LUXEL V/VX-SERIES PLATESETTER

ENGINEERS REFERENCE GUIDE

6800101004

FUJIFILM Electronic Imaging Ltd. Fujifilm House Boundary Way Hemel Hempstead Hertfordshire HP2 7RH England

Tel: 01442 213440 Fax: 01442 343432 Registered Number: 3244452

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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 becomes 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. Personnel must read the contents of any documentation supplied and used with this product BEFORE commencing 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 manual. 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 jurisdictions; Windows and Windows NT are trademarks of Microsoft Corporation that may be registered in ceratin jurisdictions; All other company names, products or brand names are trademarks of their respective holders.

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About this Guide

This Guide provides qualified Luxel service engineers with sufficient information to maintain all variants of the Luxel V/Vx-Series 9600 (B1) and 6000 (B2) CTP system. It assumes the engineer has attended an authorised training course and is familiar with laser safety, product features and service procedures required to ensure the long-term operation of the equipment. The Guide is divided into three volumes: Volume 1 - System Overview. Describes the main product features, configurations, modules and principles of operation. Volume 2 - System Description. Describes the modules and assemblies in more detail and shows how they are interconnected. Volume 3 - System Replacements. Shows how to remove and replace field replaceable units (FRUs), and carry out any set ups. System faults are reported as error codes that appear on the MMI console. An up to date listing of the code numbers, fault descriptions and recommended recovery steps are in a regularly updated Guide called Luxel V/Vx-Series Error Codes. This is available as a Manual from the FFEI Service Information Online site.

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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

Volume 1 Chapter 2 Introducing Luxel Modules

Luxel System - Modules and Variants .................................................................2-1 Introducing Plate Handling ...................................................................................2-3
Plate Handling Board (FHMB) ..............................................................................2-5
FHMB Operation ..................................................................................................2-7 Stepper Motors: ................................................................................................2-9

Introducing Traverse Scanning ...........................................................................2-10

Traverse Board (STB)............................................................................................2-11
STB Main Functions............................................................................................2-12

Cassette and Media Database Control ...............................................................2-15 Plate Processor Interface Commands .................................................................2-16

Introducing Image Expose ...................................................................................2-17

Image Expose Modules and Operations ............................................................2-17

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Image Data and Optical Path ..............................................................................2-20 Optics Base Module Control ...............................................................................2-22
Optical Motor Control (VBOMB)........................................................................2-22 CAN Control Interface: ..................................................................................2-24 Diagnostics: ....................................................................................................2-24 MPU: ..............................................................................................................2-24 Flash Memory:................................................................................................2-24 Voltages and Drives: ......................................................................................2-24 Motor Drivers.................................................................................................2-25 EOD Control .......................................................................................................2-25 EODHV Operation .........................................................................................2-25 Introducing Luxel Power and Control ..............................................................2-28 Luxel System Board (LSB) ...................................................................................2-28 LSB System Control ............................................................................................2-28 LSB Image Data Path ..........................................................................................2-30

CAN Network Control ........................................................................................2-33 Power Distribution Control .................................................................................2-35

Volume 1 Chapter 3 Servicing Safety Practice

Health and Safety at Work (All Variants) ..........................................................3-1
Warnings and Cautions .........................................................................................3-1 Clothing and Jewellery ..........................................................................................3-2 Equipment and Tools .............................................................................................3-2 Site Safety Rules ......................................................................................................3-2

Laser Safety ................................................................................................................3-2

Manual Shutter Control .........................................................................................3-2 General Laser Warnings ........................................................................................3-3 Safety Warnings ......................................................................................................3-4
A DLA Room ........................................................................................................3-4 A DLA Curtain .....................................................................................................3-5

Mains Rating Labels ...............................................................................................3-5 Drum and Traverse Warning Labels ....................................................................3-6 Optics Base Warning Labels ..................................................................................3-8 RFI, Interlock and Filter Box Warning Labels .....................................................3-9 Drum Vacuum Pump Warning Label ................................................................3-12 Interlocked Warning Labels (Automatic Only) .................................................3-13 Plate Transport Module Warning Labels ...........................................................3-14 Autofeeder Warning Labels ................................................................................3-15 Safety Devices .......................................................................................................3-17 Unattended Equipment .......................................................................................3-17 Dust Prevention ....................................................................................................3-18 Electrical Safety .....................................................................................................3-18

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Mechanical Safety .................................................................................................3-18 Chemical Safety ....................................................................................................3-19 Spinner Safety .......................................................................................................3-19

Moving Parts Safety............................................................................................3-19 Acoustic Noise Safety .........................................................................................3-19

Safety Interlocks (All Variants) ...........................................................................3-19

Interlocked Covers ...............................................................................................3-20 Locked Covers ......................................................................................................3-21

Emergency Stop Circuit ........................................................................................3-22

Emergency Stop Operation.................................................................................3-22

Mechanical Safety ...................................................................................................3-24

At the Autofeeder (Automatic Only)..................................................................3-24 At the Plate Transport Module (Automatic Only) ............................................3-24 Inside the Drum (All Variants)............................................................................3-24

Antistatic Precautions (All Variants) .................................................................3-24

Field Service Antistatic Kit ..................................................................................3-25

Volume 2 Chapter 1 Platesetter Diagnostics

Introducing Luxel CTP Diagnostics .....................................................................1-1 Booting the Platesetter .............................................................................................1-2
Boot Sequence and Initialisation ...........................................................................1-4

Introducing Main Diagnostics ...............................................................................1-6 Introducing Diagnostic Tests .................................................................................1-7

System Self-Test Error Codes ................................................................................1-7 System Self-Test Descriptions ...............................................................................1-8
ROM Test..............................................................................................................1-8 RAM Test..............................................................................................................1-8 Interrupt Tests ......................................................................................................1-8 Registry Check......................................................................................................1-8 PSU Voltage Supply Check...................................................................................1-8 NVRAM Integrity Test..........................................................................................1-8 Stepper Motor Tests..............................................................................................1-8 Datum Tests......................................................................................................1-8 Full Travel Tests ...............................................................................................1-9 Plate Handling Motors .....................................................................................1-9 DC Motor Assembly Tests ....................................................................................1-9 Spinner Checks .....................................................................................................1-9 Optics Checks .......................................................................................................1-9 Output Data Path Checks .....................................................................................1-9 Processor Comms Checks .....................................................................................1-9

MMI Test Images ....................................................................................................1-9

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Describing MMI Error Codes .............................................................................1-10

Types of Errors......................................................................................................1-10 Fatal Error Closedown Sequence ........................................................................1-11 Error Logging ........................................................................................................1-11 Using the SaveLog Utility ....................................................................................1-11

How to Use Main Diagnostics .............................................................................1-12

Setting up a Terminal Window ...........................................................................1-12 Accessing Diagnostics ..........................................................................................1-13
Main Menus........................................................................................................1-13 Obtaining the Diagnostics Menu ........................................................................1-13

Entering Diagnostic Commands .........................................................................1-13 Using Global Commands ....................................................................................1-14 Using Verbose .......................................................................................................1-15 Running Soak Tests ..............................................................................................1-16
Using the Debug Utility......................................................................................1-16 ddbg ...............................................................................................................1-17 edbg................................................................................................................1-17 ddeb................................................................................................................1-17 Using Script Commands.....................................................................................1-18 recordscript ....................................................................................................1-18 showscript ......................................................................................................1-18 runscript .........................................................................................................1-18 deletescript .....................................................................................................1-18 listscripts ........................................................................................................1-18 zeroscripts ......................................................................................................1-18 Obtaining Command Line Help .........................................................................1-18

Running Main Diagnostics ...................................................................................1-19 Using Log Utils Menus .........................................................................................1-19

log_utils menu ......................................................................................................1-20 log_utils/configuration menu ............................................................................1-22 log utils/nvram menu..........................................................................................1-23

Using Test Menus ...................................................................................................1-27

test/basic menu ....................................................................................................1-27 test/registry menu ...............................................................................................1-27 test/optics_motors menu ....................................................................................1-28 test/traverse menu ...............................................................................................1-29 test/spinner menu ................................................................................................1-29 test/optics menu...................................................................................................1-30 test/processor menu ............................................................................................1-30

Using Service Menus .............................................................................................1-30

service/memory menu ........................................................................................1-31 service/evt menu..................................................................................................1-31 service/remote menu ...........................................................................................1-32

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service/optics menu .............................................................................................1-32

service/optics/laser menu..................................................................................1-32 service/optics/motors menu..............................................................................1-35 service/optics/motors/move_motors (optics)...............................................1-36 service/optics/motors/simulate menu..........................................................1-37 service/optics/optics_mmi setup screensM.......................................................1-37

service/motors menu (stepper) ..........................................................................1-37 service/sensors menu ..........................................................................................1-39 service/time menu ...............................................................................................1-43 service/traverse menu .........................................................................................1-43 service/spinner menu ..........................................................................................1-45 service/actuators ..................................................................................................1-45 service/disk menu ................................................................................................1-46
service/disk/dfs menu.......................................................................................1-47

service/testpatns menu .......................................................................................1-48 service/job_mgr menu .........................................................................................1-50

service/image_mgr menu...................................................................................1-52

service/medproc/ ................................................................................................1-53 service/medtran menu ........................................................................................1-54 service/dbases menu ...........................................................................................1-58

service/dbases/cassette......................................................................................1-58 service/dbases/elevator.....................................................................................1-59

service/utils menu ...............................................................................................1-60

Checking Config and NVRAM Data..................................................................1-60

Introducing Configuration Data Files ................................................................1-60 Board Config Files ................................................................................................1-62
ID Data................................................................................................................1-63 History Data .......................................................................................................1-63

System Config Files ..............................................................................................1-63

ID Data................................................................................................................1-63 Revision Data......................................................................................................1-63 History Data .......................................................................................................1-63

System Registry Files............................................................................................1-64 HDD Data Files .....................................................................................................1-64 NVRAM Data ........................................................................................................1-65 Updating the System Registry.............................................................................1-65
Using Display_Registry ......................................................................................1-66 Using Update_Registry.......................................................................................1-66

Upgrading Embedded Firmware .......................................................................1-66 Setting Up Persistent Images ...............................................................................1-67

Creating a PI (Celebrant RIP) ..............................................................................1-67

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Running MMI Self-Tests .......................................................................................1-69 Using Media Tools .................................................................................................1-70

Deleting and Editing a PI (Celebrant RIP) .........................................................1-68 Creating a PI (Rampage RIP) ..............................................................................1-68

Fully-Automatic ....................................................................................................1-70 Manual and Semi-Automatic ..............................................................................1-70

Volume 2 Chapter 2 Plate Handling Control

Plate Handling Control Modules..........................................................................2-1
Autofeeder...............................................................................................................2-1
PTM ......................................................................................................................2-4

Imaging Engine .......................................................................................................2-7 Buffer .....................................................................................................................2-11

Plate Handling Assemblies ..................................................................................2-13

Plate Handling Sensors ........................................................................................2-13
Opto-Reflective Sensors......................................................................................2-13 Opto-Slotted Sensors ..........................................................................................2-15 Reflective/Diffused Sensor.................................................................................2-16 Micro-switch Sensor ...........................................................................................2-16 Magnet Reed Sensor ...........................................................................................2-16 Inductive Sensor .................................................................................................2-16

Plate Handling Motors .........................................................................................2-16

Stepper Motor .....................................................................................................2-16 DC Motor............................................................................................................2-17 Synchronous Motor ............................................................................................2-17

Plate Handling Solenoids ....................................................................................2-17

Plate Handling Operation and Sequence ..........................................................2-18

Autofeeder Operation.........................................................................................2-18 PTM Operation ...................................................................................................2-18 Engine Operation................................................................................................2-19 Buffer Operation.................................................................................................2-20

Plate Handling Control Sequence .......................................................................2-21

At the Autofeeder ...............................................................................................2-21 At the PTM .........................................................................................................2-22 At the Engine (Fully-Automatic with Punch) .....................................................2-26 At the Engine (Non-Punch with Large Plates)....................................................2-32 At the Engine (Non-Punch with Small Plates) ....................................................2-37 At the Buffer (B1 Variants Only).........................................................................2-42 Reversing the Cassette (Fully-Automatic) ..........................................................2-43 Recovering from Plate Errors (Fully-Automatic) ................................................2-45

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Plate Handling Flowcharts ..................................................................................2-46

Volume 2 Chapter 3 Plate Handling Modules

Introducing Plate Handling Modules ..................................................................3-1
Plate Handling Modules and Variants .................................................................3-2 Autofeeder ...............................................................................................................3-3 Plate Transport Module .........................................................................................3-4 Engine ......................................................................................................................3-5 Buffer........................................................................................................................3-7

Autofeeder Plate Handling Modules ...................................................................3-8

Autofeeder Control Assemblies ............................................................................3-8
Elevator Control Box.............................................................................................3-9 RFI Filter .............................................................................................................3-10 Inverter ...............................................................................................................3-11 Error Codes ....................................................................................................3-13 Contactor ............................................................................................................3-14 Elevator Interlock Controls .................................................................................3-14 Elevator Control PCB .........................................................................................3-16 Elevator Distribution PCB ..................................................................................3-18 Cassette Door Lock Solenoid ..............................................................................3-20 Trolley Docking Indicator...................................................................................3-20 Z-Direction Arm .................................................................................................3-21 Absolute Limit Safety Switch..............................................................................3-22 Autofeeder Motors..............................................................................................3-22 Elevator Motor/Gearbox (BM26) ...................................................................3-22 Autofeeder Solenoids..........................................................................................3-22 Autofeeder Sensors.............................................................................................3-23

Autofeeder Mechanical Assemblies ...................................................................3-24

Main Frame Assemblies......................................................................................3-25 Multi-Cassette Housing Assembly .....................................................................3-25 Cassette Loading Door........................................................................................3-26 Elevator Frame....................................................................................................3-26 Sensor Vane ........................................................................................................3-27 Elevator Drive Assemblies..................................................................................3-27 Trolley.................................................................................................................3-29 Trolley Assemblies .........................................................................................3-29 Trolley Operation ...........................................................................................3-29 Cassette...............................................................................................................3-30

Plate Transport Modules ......................................................................................3-33

PTM Control Assemblies ....................................................................................3-33

Cassette Assemblies........................................................................................3-30

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FHMB PCB (2) Assembly....................................................................................3-34 FHMB PCB (3) Assembly....................................................................................3-38 PTM Distribution PCBs ......................................................................................3-43 Sensor Distribution PCB .................................................................................3-43 24 V Distribution PCB (New) .........................................................................3-44 Cassette ID PCB..............................................................................................3-45 Motor Assemblies and Operations .....................................................................3-46 PTM Solenoids and Relays .................................................................................3-47 PTM Sensors .......................................................................................................3-47

PTM Mechanical Modules ...................................................................................3-51

X-Direction Door ................................................................................................3-51 Cassette Forward ................................................................................................3-52 Cassette Forward Assembly ...........................................................................3-52 Cassette Forward Operation...........................................................................3-53 Stack (Height) Increment ....................................................................................3-54 Feed Head...........................................................................................................3-55 Antistatic Brush ..................................................................................................3-56 Retard Pad ..........................................................................................................3-57 Interleaf Diverter and Drive Roller .....................................................................3-58 Plate Transport Guides .......................................................................................3-59

Engine Plate Handling Modules .........................................................................3-61

Engine Control Assemblies .................................................................................3-61
FHMB PCB (1) Assembly....................................................................................3-62 FHMB PCB (4) Assembly....................................................................................3-66 Engine Distribution PCBs ...................................................................................3-71 Sensor Distribution PCB (Output) ..................................................................3-72 Sensor Distribution PCB (Input).....................................................................3-73 24V Distribution PCB (New) ..........................................................................3-73 Registration Pin Isolation PCB............................................................................3-74 Motors ................................................................................................................3-75 Solenoids and Relays ..........................................................................................3-77 Sensors................................................................................................................3-77 Mixer Fan............................................................................................................3-81

Engine Mechanical Modules ...............................................................................3-81

Plate Loading Platform .......................................................................................3-86 Input Module......................................................................................................3-87 Output Module ...................................................................................................3-88 Drum ..................................................................................................................3-90 Transport Push Bar (Spring) ...............................................................................3-91 Punch, Registration and Centerer (New Billows) ...............................................3-93 Using Punch Diagnostic Commands ..............................................................3-94 Punch Mechanism Assembly .........................................................................3-94 Punch Mechanism Operation .........................................................................3-95

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Registration Mechanism Assembly ................................................................3-95 Registration Mechanism Operation ................................................................3-96 Centerer Mechanism Assembly......................................................................3-96 Centerer Mechanism Operation .....................................................................3-96 Punch Configurations .........................................................................................3-96 Punch, Registration and Centerer (Fuji)..............................................................3-98 Registration Module ...........................................................................................3-99 Swing Roller Module ........................................................................................3-100 Chad Tray (Punch Only)...................................................................................3-101

Buffer Plate Handling Modules ........................................................................3-102

Buffer Control Assemblies .................................................................................3-102
Buffer Control Modules ....................................................................................3-102

Buffer Assemblies (New) ...................................................................................3-104

Inter-Module Connections and Control ..........................................................3-105

Autofeeder-to-PTM Interconnections ...............................................................3-105 PTM-to-Engine Interconnections ......................................................................3-105 Buffer-to-Engine Interconnections ....................................................................3-106

Volume 2 Chapter 4 Traverse Scan Modules

Introducing the Traverse Scan Modules .............................................................4-1
Beam Assemblies ....................................................................................................4-1 Traverse Carriage Assemblies ...............................................................................4-2
Traverse PCB ........................................................................................................4-5 Location ............................................................................................................4-5 LEDs and Links ................................................................................................4-5 Traverse PCB Connectors .................................................................................4-5 Connector Pin Descriptions ..............................................................................4-6 Test Points ........................................................................................................4-6 Traverse PCB Functional Description ...................................................................4-6

Media Scan System Description ............................................................................4-7

MPU Controller ................................................................................................4-6

Scanning Overview ................................................................................................4-7

Mixer Fan and Baffles ...........................................................................................4-8 Traverse PCB Imaging Control .............................................................................4-8 Scan Interlock Protection ......................................................................................4-8 Traverse Diagnostics.............................................................................................4-8 Umbilical Interface................................................................................................4-8

Spinner Control Subsystem ...................................................................................4-8

Spinner Encoder ...................................................................................................4-9 Spinner Controller ................................................................................................4-9 Spinner Diagnostics ..............................................................................................4-9 Spinner Condition Sensing and Braking...............................................................4-9

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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

Volume 2 Chapter 5 Media Expose Modules

Media Expose System ..............................................................................................5-1
Optics Base Modules ..............................................................................................5-1
Laser Module ........................................................................................................5-5 Laser Module Assemblies.................................................................................5-5 Photo Diode (PD) PCB..........................................................................................5-8 Laser Diode (LD) PCB ..........................................................................................5-9 Laser Air Temperature and Humidity Control.....................................................5-9 Beam Shifter........................................................................................................5-10 Waveplate...........................................................................................................5-11 Electro-Optic Deflector (EOD) ............................................................................5-11 Beam Combiner ..................................................................................................5-12 Neutral Density (ND) Filter ................................................................................5-12 Position Detector (POD) .....................................................................................5-13 Focus Adjust .......................................................................................................5-14 Aperture Control (Spot Size) ..............................................................................5-15 Optics Lenses .....................................................................................................5-16 Optics Mirrors ....................................................................................................5-16 Motors and Sensors ............................................................................................5-17 EODHV Module .................................................................................................5-17

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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

Volume 2 Chapter 6 Power and Control Modules

Introducing Power and Control Modules ..........................................................6-1
Accessing Engine Assemblies ...............................................................................6-1

System Power Distribution ....................................................................................6-2

AC Mains Power Pre-Requirements.....................................................................6-2 Mains Filter Box ......................................................................................................6-3 System AC/DC Cable Distribution ......................................................................6-3 System DC Cable Distribution ..............................................................................6-4

Interlock Box Modules ............................................................................................6-6

Interlock Box Functions .........................................................................................6-6 External I/O Interconnections ..............................................................................6-7 Mains Input and Emergency Stop Control ..........................................................6-9
Mains Input Control Assemblies ..........................................................................6-9 Emergency Stop Control...................................................................................6-9 Emergency Stop Replacements.......................................................................6-11

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Drum Vacuum Control ........................................................................................6-11 Interlocks Control .................................................................................................6-11

Interlock Box Assemblies ...............................................................................6-11 Interlock Replacements ..................................................................................6-12 Interlock Checks .............................................................................................6-12 Interlock Operation ........................................................................................6-12 External Interlocks..........................................................................................6-16 RFI Box Modules ....................................................................................................6-16 RFI Box Layout and Assemblies .........................................................................6-16 RFI Box External I/O Connections .....................................................................6-18

RFI Box - DC Power Modules..............................................................................6-19

PSU 1 ......................................................................................................................6-19 Fan Assemblies .....................................................................................................6-20
Fan Assembly .....................................................................................................6-20

System Control Fusing .........................................................................................6-20 Power Filter PCB ..................................................................................................6-21

Power Filter Assembly........................................................................................6-21 Location..........................................................................................................6-21 Connectors......................................................................................................6-21 Connector Pin Descriptions ............................................................................6-21 Power Filter PCB Operation ...............................................................................6-22

RFI Box - Image Processing Modules ................................................................6-23

Electro-Optical Deflector Driver (EODD) PCB..................................................6-23
EODD PCB Assembly .........................................................................................6-23 Location..........................................................................................................6-24 Connectors......................................................................................................6-24 Connector Pin Descriptions ............................................................................6-24 Fuses...............................................................................................................6-24 LEDs and Links ..............................................................................................6-24 Test Points ......................................................................................................6-24 EODD PCB Operation ........................................................................................6-25 EOD DIFF Deflector .......................................................................................6-26 System Board (LSB) PCB......................................................................................6-26 System PCB Assembly ........................................................................................6-26 Location..........................................................................................................6-26 Connectors......................................................................................................6-26 Connector Pin Descriptions ............................................................................6-27 Fuses...............................................................................................................6-27 ICs (Main Devices) .........................................................................................6-27 LEDs ...............................................................................................................6-28 Links...............................................................................................................6-28 Test Points ......................................................................................................6-29 Dongle ................................................................................................................6-29

Hard Disk Drives (HDD) .....................................................................................6-29

Disk Drive Assembly ..........................................................................................6-29

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MMI and External Alert ........................................................................................6-30

Man Machine Interface (MMI) ............................................................................6-30 External Alert Control ..........................................................................................6-33
Fuses...............................................................................................................6-31

Volume 2 Chapter 7 Vacuum and Air Control

Vacuum and Contamination Control ..................................................................7-1
Drum Vacuum and Drum Blow............................................................................7-1 Contamination Control ..........................................................................................7-1
Contamination Managementl ...............................................................................7-3

Drum Vacuum and Drum Blow............................................................................7-4

Drum Configurations .............................................................................................7-4
Drum with Manifolds ...........................................................................................7-4 Drum with Chambers ...........................................................................................7-5

Drum Vacuum and Blow Assemblies ..................................................................7-6 Drum Vacuum and Blow System .........................................................................7-7
B1 Fully-Auto and Manual (without a Punch)......................................................7-8 B1 Fully-Auto (with a Punch) .............................................................................7-12 B2 Semi-Auto and Manual (without a Punch) ....................................................7-16

Air Knife ..................................................................................................................7-18

Air Knife (Compressor)........................................................................................7-18 Air Knife (Fan Blower) .........................................................................................7-19 Servicing the Air Knife .........................................................................................7-20
Fan Blower ..........................................................................................................7-20 Control Relay (BV23) ..........................................................................................7-21

Air Purifier (PAT) ...................................................................................................7-21

Servicing the PAT .................................................................................................7-22 Service Filtering for the Optics Base ...................................................................7-22

Volume 2 Chapter 8 System Cabling Descriptions

Cable Pin Descriptions ............................................................................................8-1
I/LOCKS_MAINS (9970-0119) ..............................................................................8-1 MAINS_RFI_IN (9970-0122) ..................................................................................8-2 DISK_PWR (9970-0129) ..........................................................................................8-2 EOD (9970-0135) .....................................................................................................8-2 CAN2 (9970-0138) ...................................................................................................8-3 MMI (9970-0139) .....................................................................................................8-4 INT_S41/S42 (9970-0140) .......................................................................................8-5 ENG_INT (9970-0142) ............................................................................................8-5 INT_STAT (9970-0143) ...........................................................................................8-7

P RELIMINARIES

CAN5_ENG (9970-0145) ........................................................................................8-8 ENG_FHMBPWR (9970-0146) ...............................................................................8-8 CAN3_ENG (9970-0147) ......................................................................................8-10 PUMP/PTM_PWR (9970-0150) ...........................................................................8-11 FEED_INT (9970-0152) .........................................................................................8-11 CAN5_INT (9970-0155) ........................................................................................8-12 PWR3_INT (99700156) .........................................................................................8-12 CAN3_INT (9970-0157) ........................................................................................8-13 ENG_M7 (9970-0159)............................................................................................8-14 RIB/RIB2 (9970-0161) ...........................................................................................8-15 BUFF_M7 (9970-0168) ..........................................................................................8-15 INT_S62/S71 (9970-0177).....................................................................................8-16 INT_S56/57/65 (9970-0178) ................................................................................8-16 ENG_S4 (9970-0183) .............................................................................................8-17 INT_S49/S50 (9970-0186).....................................................................................8-17 ENG_S5 (9970-0187) .............................................................................................8-18 INT_S52 (9970-0188) .............................................................................................8-18 ENG_S10/11 (9970-0190) .....................................................................................8-18 ENG_S14/12/3 (9970-0194) .................................................................................8-19 ENG_S8/S9 (9970-0195) .......................................................................................8-20 INT_M22ASSY (9970-0198) .................................................................................8-21 INT_S55/59 (9970-0210) .......................................................................................8-22 INT_S66/S53 (9970-0214).....................................................................................8-22 INT_OUT (9970-0216) ..........................................................................................8-23 RIB7 (9970-0219) ...................................................................................................8-24 ENG_DIAGS (9970-0221) .....................................................................................8-26 ALERT (9970-0223) ...............................................................................................8-26 INT_MAINS (9970-0226) .....................................................................................8-27 RIB8 (9970-0229) ...................................................................................................8-27 ELV_CTRL (9970-0230) ........................................................................................8-28 MAINS_ELV_IN (9970-0231) ..............................................................................8-29 ELV_IN (9970-0236) ..............................................................................................8-29 ELV_LOCK (9970-0237) .......................................................................................8-30 ELV_CON_24V (9970-0238) ................................................................................8-31 ENG_PROC (9970-0239) ......................................................................................8-32 MAINS_INT_PUMP (9970-0240) ........................................................................8-32 MAINS_DIST (9970-0243) ....................................................................................8-33 INT_EMERG (9970-0246) .....................................................................................8-33 I/LOCK_DC (9970-0252) .....................................................................................8-34 I/LOCK_EMERG (9970-0253) .............................................................................8-36

P RELIMINARIES

INT_M20/M27 (9970-0255) .................................................................................8-37 INT_M25/M21 (9970-0256) .................................................................................8-37 ENG_M1 (9970-0281)............................................................................................8-38 ENG_M2 (9970-0282)............................................................................................8-38 ENG_M4 (9970-0283)............................................................................................8-38 INT_S45ASSY (9970-0284) ...................................................................................8-39 INT_S76 (9970-0285) .............................................................................................8-40 I/LOCK_PUMPCTRL (9970-0287)......................................................................8-40 BUFF_S19/20 (9970-0288) ....................................................................................8-41 ENG_S19/20 (9970-0289) .....................................................................................8-41 ENG_S21 (9970-0291) ...........................................................................................8-42 ENG_S79 (9970-0292) ...........................................................................................8-42 MIX_FAN (9970-0295) ..........................................................................................8-43 MFAN (9970-0296) ................................................................................................8-43 BUFF_LOCK (9970-0298) .....................................................................................8-43 PROC_COMMS (9970-0306) ................................................................................8-44 PSU_I/LOCK (9970-0310) ....................................................................................8-44 ELV_TLOCKSOL (9970-0379) .............................................................................8-45 ENG_BLOW (9970-0380)......................................................................................8-45 ENG_S3/S12 (9970-0406) .....................................................................................8-46 ENG_S109/110 (9970-0390) .................................................................................8-46 ENG_S100/103 (9970-0392) .................................................................................8-47 MAINS_PSU (9970-0420) .....................................................................................8-48 PSU (9970-0421) ....................................................................................................8-48 DISK DATA (9970-0423) ......................................................................................8-50 MAINS_DIST (9970-0424) ....................................................................................8-50 CAN1 (9970-0425) .................................................................................................8-51 VBOMB_PWR (9970-0427) ...................................................................................8-51 24V_ENG (9970-0428)...........................................................................................8-52 EDGE_LASER (9970-0434) ...................................................................................8-52 VBOMB_SENSORS (99700435) ...........................................................................8-53 VBOMB_LPD (9970-0436) ....................................................................................8-54 VBOMB_LPDM (9970-0437) ................................................................................8-55 VBOMB_APM (9970-0438) ..................................................................................8-55 VBOMB_NDM (9970-0439)..................................................................................8-56 VBOMB_FOCM (9970-0440) ................................................................................8-56 PSU_CTRL (9970-0442) ........................................................................................8-57 VBOMB_POD (9970-0443) ...................................................................................8-57 I/LOCK_MAIN (9970-0444) ................................................................................8-58 ENG_S6/S15 (9970-0445) .....................................................................................8-59

P RELIMINARIES

ENG_BLOW (9970-0446) .....................................................................................8-59 I/LOCK_DC (9970-0447) .....................................................................................8-60 EDGE_DETECT (9970-0448) ................................................................................8-63 LSB_DATA_VBOMB (9970-0449) .......................................................................8-63 VBOMB_IHPEN (9970-0450) ...............................................................................8-64 REG_PIN (9970-0451) ...........................................................................................8-65 REG_FHMB (9970-0452) ......................................................................................8-65 COMP_PANEL (9970-0453) ................................................................................8-66 COMP_MAINS (9970-0454) .................................................................................8-66 ILOCK_COMP (99700-455)..................................................................................8-66 ILOCK_CTRL (9970-0456) ...................................................................................8-67 SOL_CTRL (9970-0457) ........................................................................................8-67 RIB3 (9970-0458) ...................................................................................................8-68 ENG_S1/2 (9970-0459) .........................................................................................8-68 VAC (9970-0460) ...................................................................................................8-69 ENG_M6 (9970-0461)............................................................................................8-70 ENG_M38 (9970-0462) ..........................................................................................8-70 ENG_S118 (9970-0463) .........................................................................................8-70 ENG_M10 (9970-0464) ..........................................................................................8-71 ENG_M11 (9970-0465) ..........................................................................................8-71 ENG_S114/116/113 (9970-0466) .........................................................................8-71 ENG_M3/5 (9970-0467) .......................................................................................8-72 ENG_M36/37 (9970-0468) ...................................................................................8-73 INV_MOT (9970-0471) .........................................................................................8-73 VBOMB_FAN (9970-0472) ...................................................................................8-74 CAN_FHMB1_4 (9970-0473) ...............................................................................8-74 PUMP (9970-0479) ................................................................................................8-75 ENG_FHMB_PWR (99700480) ............................................................................8-76 ILOCK_LINK (99700481) .....................................................................................8-76 BUFF_LINK (9970-0482) ......................................................................................8-77 ENGB1_S118 (9970-0490) .....................................................................................8-77 ENGB1_M10 (9970-0491) .....................................................................................8-77 ENGB1_S1/S2 (9970-0492) ..................................................................................8-78 ILOCK_LINK (9970-0493) ....................................................................................8-78 ENGB1_M11 (9970-0494) .....................................................................................8-79 ENGB1_S114/116/113 (9970-0495).....................................................................8-79 ENG_1BHP_S3/S10/S14 (9970-0497) .................................................................8-80 ENG_IHP_M3/5 (9970-0498) ..............................................................................8-81 ENG_FPD_S21 (9970-0499) ..................................................................................8-82 MAN_STOP (9970-0500) ......................................................................................8-82

P RELIMINARIES

SEMI_S109/110 (9970-0501) ................................................................................8-82 SEMI_M36/37 (9970-0502)...................................................................................8-83 BV41PUNCH_LINK (9970-0503) ........................................................................8-83 BV41WEB_LINK (9970-0504) ..............................................................................8-84 EXT_M11 (9970-0505) ...........................................................................................8-84 FRONT_SENSOR_EXT (9970-0506) ....................................................................8-85 B1_FRONTSENSOR (9970-0507) .........................................................................8-86 B2_FRONTSENSOR (9970-0508) .........................................................................8-87 B2_M11 (9970-0509) ..............................................................................................8-87 B1_M11 (9970-0510) ..............................................................................................8-88 INT_STAT (9970-0511) .........................................................................................8-88 ENG_BLOW_AUTO_WEB (9970-0512) .............................................................8-89 ENG_BLOW_AUTO_PUNCH (9970-0516)........................................................8-89 AIRKNIFE_VAC (9970-0517) ..............................................................................8-90 XBLW3_IPWR (9970-0518) ..................................................................................8-91

Volume 2 Chapter 9 System Cabling Views Volume 3 Chapter 1 Routine Maintenance

Field Service Tools....................................................................................................1-1 Overriding the Interlocks .......................................................................................1-2 Opening Service Covers ..........................................................................................1-3
Manual and Semi-Automatic ................................................................................1-3 Fully-Automatic ......................................................................................................1-3

Maintenance Schedule.............................................................................................1-4 Cleaning Procedures ................................................................................................1-5

Cleaning the Spinner Mirror and L6 Lens ...........................................................1-5
Focusing Lens (L6)................................................................................................1-5

Cleaning the Traverse Assemblies ........................................................................1-6

Linear Scale and Drive Rail...................................................................................1-6 Readhead ..............................................................................................................1-7 Drive Rail Wiper ...................................................................................................1-7

Cleaning the PTM Assemblies ..............................................................................1-7

Feed Head ........................................................................................................1-7 Retard Pad ........................................................................................................1-7 Guides and Surfaces .........................................................................................1-7 Air Knife ...........................................................................................................1-7 Cleaning the Engine Assemblies ...........................................................................1-8 Drum ................................................................................................................1-8 Input and Output Modules ..............................................................................1-8 Punch................................................................................................................1-8

P RELIMINARIES

Push Bar (Cleaning)..........................................................................................1-8 LPD ..................................................................................................................1-8 MMI Touchpanel ..............................................................................................1-8 FPD Filter Lens .................................................................................................1-8 PAT Air Filter ...................................................................................................1-8 Cleaning the Module Interior ................................................................................1-9 Cleaning the Cassette .............................................................................................1-9

Cleaning the Elevator .............................................................................................1-9

Maintenance Procedures ........................................................................................1-9

Interlock Checks .....................................................................................................1-9 Punch Checks ..........................................................................................................1-9 Push Bar Flake Containment Checks .................................................................1-10 Drum Blow Checks...............................................................................................1-10 Laser Extinction Level Checks ............................................................................1-10 Pre-Cautionary Checks ........................................................................................1-11 Absolute Limit Sensor Check ..............................................................................1-12
Trolley and Cassette Checks ...............................................................................1-12 Trolley ............................................................................................................1-12 Cassette ..........................................................................................................1-12 Paper Detect Sensor Check ..................................................................................1-13

Light-Tight Checks ...............................................................................................1-13

Modules ..............................................................................................................1-13 Cassette...............................................................................................................1-13

Checking the Traverse ...........................................................................................1-14

Aligning the Carriage and Ball Cage ..................................................................1-14 Engine Traverse Level Check ..............................................................................1-14

Checking the Platesetter Output .........................................................................1-16

All Platesetter Variants ........................................................................................1-16
Check Image Form Adjustment ..........................................................................1-16 Check Expose Tint Quality .................................................................................1-16 Check Image Quality ..........................................................................................1-17

Platesetters Fitted With a Punch .........................................................................1-17

Check Plate Load in Drum..................................................................................1-17 Check Image Position and Skew.........................................................................1-19 Check for Punch Crop Accuracy.........................................................................1-19 Check Punch Centering ......................................................................................1-20 Set Image Traverse Centre Position ....................................................................1-21 Set Image Base Offset..........................................................................................1-22

Platesetters Fitted Without a Punch ...................................................................1-23

Check Image Skew Accuracy..............................................................................1-23 Check Edge Detect Function...............................................................................1-24 Check Image Start and Edge Accuracy ...............................................................1-24

P RELIMINARIES

Set Image Base Offset..........................................................................................1-25 Set Image Edge Sensor Offset .............................................................................1-26

Volume 3 Chapter 2 Plate Handling Service Procedures

Starting the Service Procedures.............................................................................2-1
General Plate HandlingReplacements..................................................................2-1
Sensor (Reflective-Opto PCB) Removal ................................................................2-1 Sensor (Opto-Slotted) Removal.............................................................................2-2 FHMB Replacement..............................................................................................2-3

Autofeeder Servicing ...............................................................................................2-4

Accessing Autofeeder Assemblies ........................................................................2-4
RFI Filter Replacement..........................................................................................2-4 Inverter Replacements ..........................................................................................2-5 Inverter Fault-finding .......................................................................................2-5 Inverter Replacement .......................................................................................2-6 Contactor Replacement.........................................................................................2-7 Elevator Control PCB Replacement ......................................................................2-7 Elevator Distribution PCB Replacement ...............................................................2-7 Setting Up the Elevator Shelf/Rail Alignments ....................................................2-7 Cassette Door Lock Replacement........................................................................2-11 Docking Lamp Replacement...............................................................................2-11 Docking Sensor Replacement .............................................................................2-12 Z-Direction Control Removal .............................................................................2-12 Z-Direction Control Replacement .......................................................................2-12 Absolute Limit Safety Switch Replacement ........................................................2-12 Elevator Motor (BM26) Replacement..................................................................2-13 Chain Tensioner Spring Replacement.................................................................2-13

Plate Transport Module Servicing ......................................................................2-15

Accessing PTM Assemblies .................................................................................2-15 PTM Sensor Replacements and Setups ..............................................................2-16
BS55 Sensor Setup...............................................................................................2-16 BS51 Sensor Setup...............................................................................................2-17

X-Direction Door ..................................................................................................2-18

X-Direction Door Replacement ...........................................................................2-18 Motor (BM27) Removal.......................................................................................2-19

Cassette Forward ..................................................................................................2-19

Cassette Forward Removal .................................................................................2-19 Cassette Forward Replacement...........................................................................2-19 Motor (BM20) Removal.......................................................................................2-20 Drive Belt Removal .............................................................................................2-20

P RELIMINARIES

Stack Increment ....................................................................................................2-20

Stack Increment Removal ...................................................................................2-20 Stack Increment Replacement.............................................................................2-21 Motor (BM21) Removal ......................................................................................2-21 Drive Belts Removal ...........................................................................................2-21

Feed Head .............................................................................................................2-21

Feed Head Removal............................................................................................2-21 Feed Head Replacement .....................................................................................2-22 Stack Height Position Check ..........................................................................2-23 Motor (BM23) Removal ......................................................................................2-24 Motor (BM22) Removal ......................................................................................2-24

Retard Pad .............................................................................................................2-24

Retard Pad Removal ...........................................................................................2-24 Retard Pad Replacement.....................................................................................2-25

Interleaf Diverter and Drive Roller.....................................................................2-25

Interleaf Diverter Removal .................................................................................2-25 Interleaf Diverter Replacement...........................................................................2-25 Interleaf Drive Rollers Removal..........................................................................2-26 Interleaf Drive Roller Replacement.....................................................................2-26

Transport Plate Guides ........................................................................................2-26

Pre-Diverter Plate Guide Removal .....................................................................2-26 Post-Diverter Plate Guide Removal ....................................................................2-27 Engine Interface (Output) Plate Guide Removal ................................................2-27

Engine Servicing .....................................................................................................2-27

Accessing Engine Assemblies .............................................................................2-27
Removing the Drum End Caps...........................................................................2-28

Loading Platform ..................................................................................................2-29

Loading Platform Removal (Manual) .................................................................2-29

Input Module ........................................................................................................2-31

Input Module Removal (All Variants) ................................................................2-31 Roller and Drive Belt Removal ...........................................................................2-31

Output Module .....................................................................................................2-32

Output Module Removal....................................................................................2-32 Fully-Automatic: ............................................................................................2-32 Semi-Automatic and Manual:.........................................................................2-33 Output Guide Removal ......................................................................................2-33

Transport Push Bar (Mark 2) ...............................................................................2-33

Removing the Push bar.......................................................................................2-33 Replace the Spring Shoes................................................................................2-34 Replacing the Push Bar .......................................................................................2-35 Aligning the Push Bar ....................................................................................2-35

P RELIMINARIES

Setting up the Push Bar.......................................................................................2-35

Drum Gear Segments ...........................................................................................2-36

Gear Segment Replacement ................................................................................2-36

Punch, Registration and Centerer (Billows) ......................................................2-37

Accessing Punch Assemblies ..............................................................................2-37 Complete Punch Removal ..................................................................................2-37 Accessing the Assembly .................................................................................2-37 Removing the Assembly.................................................................................2-39 Complete Punch Replacement............................................................................2-39 Punch Adjustments and Checks .........................................................................2-40 Visual Plate Punch Check...............................................................................2-41 Punch Mechanism Check ...............................................................................2-41 Registration Mechanism Check ......................................................................2-42 Centering Mechanism Check..........................................................................2-42 Punch Pin Checks ...............................................................................................2-42 Adjust Punch Pins ..........................................................................................2-42 Punch Checks .................................................................................................2-43 Registration Mechanism Replacements ..............................................................2-44 Motor (BM5) ...................................................................................................2-44 Sensors (BS10/11)...........................................................................................2-44 Registration Mechanism Checks.........................................................................2-44 Centerer Mechanism Replacements....................................................................2-44 Motor (BM3) and Gear Head ..........................................................................2-44 Sensors (BS14).................................................................................................2-44 Checking the Centerer Mechanism .....................................................................2-45 Adjusting the Centerer Mechanism ................................................................2-45 Punch Mechanism Replacements .......................................................................2-45 Motor (BM4) ...................................................................................................2-45 Sensors (BS8/9) ..............................................................................................2-45 Sensor (BS3) ....................................................................................................2-45 Punch Pins, Dies and Guides..........................................................................2-46 Punch Crop Depth Adjustment ......................................................................2-46 Drag Chain and Wiring Loom Removal .........................................................2-46 Registration Mechanism Replacements ..............................................................2-47 Motor (BM5) ...................................................................................................2-47 Sensors (BS10/11)...........................................................................................2-48 Registration Mechanism Checks.........................................................................2-48 Centerer Mechanism Replacements....................................................................2-48 Motor (BM3) and Gear Head ..........................................................................2-48 Sensors (BS12/13)...........................................................................................2-48 Sensors (BS14).................................................................................................2-49 Checking the Centerer Mechanism .....................................................................2-49

Punch, Registration and Centerer (Fuji) .............................................................2-49

Accessing the Assembly......................................................................................2-49 Removing the Assembly .....................................................................................2-49 Complete Punch Replacement............................................................................2-51

P RELIMINARIES

Punch Adjustments and Checks .........................................................................2-51 Visual Plate Punch Check...............................................................................2-52 Punch Checks .................................................................................................2-52 Replacing the Punch Pins ...............................................................................2-52 Removing the Punch Motor ...........................................................................2-53 Replacing the Chad Wipers ............................................................................2-54 Swing Roller Module (SRM) ...............................................................................2-55 Swing Roller Module Replacements ...................................................................2-55 Swing Roller Module Checks..............................................................................2-56

Registration Module .............................................................................................2-57

Registration Module Replacement......................................................................2-57

MMI .......................................................................................................................2-57
MMI ReplacementM ...........................................................................................2-57

Buffer Servicing ......................................................................................................2-57

Lowering the Buffer .............................................................................................2-57 Accessing the Buffer Assemblies ........................................................................2-60
Removing the Upper Cover (Skin) .....................................................................2-60

Motor, Gear and Sensors .....................................................................................2-61

Motor Replacement ............................................................................................2-61 Gear Replacement...............................................................................................2-61

Drive Belts and Rollers.........................................................................................2-62

Drive Belt Replacement ......................................................................................2-62 Roller Replacement.............................................................................................2-62

Buffer Alignment Check ......................................................................................2-62

Volume 3 Chapter 3 Traverse Scan Service Procedures

Starting Scan System Replacements .....................................................................3-1 Accessing Traverse Scan Modules ......................................................................3-1
Traverse Carriage Access .......................................................................................3-2

Replacing Traverse Assemblies.............................................................................3-4

Baffle Assemblies ....................................................................................................3-4 Traverse PCB ...........................................................................................................3-6 Traverse Motor .......................................................................................................3-6 Drive Rail Wiper .....................................................................................................3-7 Umbilical Cable ......................................................................................................3-8 Spinner .....................................................................................................................3-9 Ball Cage Assembly ..............................................................................................3-11 Readhead ...............................................................................................................3-11 Edge Detect PCB and Laser Diode .....................................................................3-13
Check Edge Detect Function...............................................................................3-13 Replacing the Edge Detect PCB ..........................................................................3-14

P RELIMINARIES

Replacing the Laser Diode ..................................................................................3-15 Edge Detect Setup Procedure..............................................................................3-16

Volume 3 Chapter 4 Optics Service Procedures

Starting Optics Module Replacements ................................................................4-1
Accessing Expose Modules....................................................................................4-2

Optics Replacement Setups ....................................................................................4-3

Find LPD Position...................................................................................................4-5 Update Laser Parameters.......................................................................................4-6 Clear Laser Aging Statistics ...................................................................................4-7 Set up Laser Current Limit and Start Aging Log ................................................4-8 Check Power Balance (2-Beam Only) ...................................................................4-8 Set Laser Extinction ................................................................................................4-9 Reset Beam Coincidence (2-Beam Only) ............................................................4-10 Run Beam Coincidence (2-Beam Only) ..............................................................4-10 Set up and Locate FPD .........................................................................................4-11 Set up ND Characterisation .................................................................................4-12 Reset Spinner Contamination Checks ................................................................4-12 Run Exposure Calibration ...................................................................................4-12 Set up Auto Focus .................................................................................................4-12 Set up Auto ND Wedge (2-Beam Only) .............................................................4-12 Set up Auto Threshold Wedge (2-Beam Only) ..................................................4-13 Set up Auto Coincidence Y & X (2-Beam Only) ................................................4-13 Run Auto Deflection Abs Phase (2-Beam Only) ................................................4-13 Run Auto Deflection Amp Y&X (2-Beam Only)................................................4-13 Adjust Image Form ...............................................................................................4-13 Run Expose Calibration .......................................................................................4-14 Image Base Offset .................................................................................................4-14 Edge Sensor Offset/Traverse Centre Position...................................................4-14 Check Image Quality ............................................................................................4-14

Optics Base Replacements ....................................................................................4-15

Optics Base Sensors ..............................................................................................4-15
Replace Optics Base Sensors ...............................................................................4-15 Setup Optics Base Sensors ..................................................................................4-15

Optics Base Motors ...............................................................................................4-16

ND Filter Assembly (Including SM1) .................................................................4-16 Replace ND Filter Assembly...........................................................................4-16 Setup ND Filter Assembly ..............................................................................4-16 SM2 (Focus Adjust).............................................................................................4-17 Replace SM2 ...................................................................................................4-17 Setup SM2.......................................................................................................4-18

P RELIMINARIES

SM3 (Aperture Control)......................................................................................4-18 Replace SM3 ...................................................................................................4-18 Setup SM3.......................................................................................................4-19 Laser Diode ...........................................................................................................4-20 Replace the Laser Diode .....................................................................................4-20 Setup the Laser Diode.........................................................................................4-22

Electro-Optic Deflector (EOD) ............................................................................4-22

Replace EOD Module .....................................................................................4-22 Setup the EOD ....................................................................................................4-22

Position Detector (POD) ......................................................................................4-23

Replace the POD PCB .........................................................................................4-24 Setup the POD PCB ............................................................................................4-24

Electro-Optics Deflector High Voltage (EODHV) .............................................4-25

Replace EODHV PCB .........................................................................................4-25 Setup EODHV PCB.............................................................................................4-25 Replace the HV Transformer ..............................................................................4-25 Setup the EODHV Transformers ........................................................................4-25

Laser Power Detector (LPD) ................................................................................4-26

Replace the LPD PCB..........................................................................................4-27 Setup the LPD .....................................................................................................4-28 Replace the Motor (SM4) ....................................................................................4-28 Setup the Motor (SM4)........................................................................................4-28 Replace the Sensor (S6) .......................................................................................4-28 Setup the Sensor (S6) ..........................................................................................4-29

Optics Motors Board (VBOMB) ..........................................................................4-29

Replace the VBOMB ...........................................................................................4-29 Setup the VBOMB...............................................................................................4-30

Fast Photo Detect (FPD) Sensor ..........................................................................4-30

Replace the FPD..................................................................................................4-30 Setup the FPD .....................................................................................................4-30

Exposing Test Strips ..............................................................................................4-31

Introducing the Test Strip Macros ......................................................................4-31 Using the Optics_MMI Options ..........................................................................4-32
Accessing Options ..............................................................................................4-32 Navigating Between Options..............................................................................4-32 Optics Test Pattern Setup Screen ........................................................................4-33 Final Values Screen.............................................................................................4-33 Machine Setup Screen.........................................................................................4-34 Extra Options Screen ..........................................................................................4-34 Selecting Options from Test Pattern Setup .........................................................4-35

Running Test Strips ..............................................................................................4-37

P RELIMINARIES

Manual and Semi-Automatic Machines (B1 & B2)..............................................4-37 Starting the Tests ................................................................................................4-37 Running Tests Strips.......................................................................................4-37 1: Auto Focus..................................................................................................4-38 2: Auto ND Wedge Density ............................................................................4-41 3: Auto Threshold Wedge Density .................................................................4-42 4: Auto Coincidence Beams Y.........................................................................4-42 5: Auto Coincidence Beam X ..........................................................................4-44 6: Auto Absolute Phase...................................................................................4-45 7: Auto Deflection Amplitude Beam Y ...........................................................4-47 8: Auto Deflection Amplitude Beam X ...........................................................4-49 Check Raster Quality .............................................................................................4-50 Calibrate Exposure Level ......................................................................................4-51 B1 and B2 Image Form Adjustments .................................................................4-54 Creating a Film Comparison Ruler .....................................................................4-55

Determining Horizontal Error ............................................................................4-56

Correcting Horizontal Error ...............................................................................4-57

Determining Vertical Error ..................................................................................4-59

Correcting Vertical Error ....................................................................................4-61

Set up ND Characterisation .................................................................................4-63

Volume 3 Chapter 5 Power and Control Service Procedures

Starting the Service Procedures.............................................................................5-1
RFI Box .....................................................................................................................5-1 Engine Service Side ................................................................................................5-1 Accessing the Assemblies ......................................................................................5-1 Power Supply Module (PSU1) ..............................................................................5-2
LSB Fan Replacement ...........................................................................................5-3 Power Filter PCB Replacement .............................................................................5-3 EODD PCB Replacement..................................................................................5-4 System PCB Replacement .....................................................................................5-4 HDD Replacement................................................................................................5-5

Replacing RFI Box Modules ...................................................................................5-2

Replacing Interlock and Power Modules ............................................................5-6

Mains Filter Box ......................................................................................................5-6 Interlock Box ...........................................................................................................5-6

Volume 1 Chapter A Quick Reference Data

Useful Service Commands .................................................................................... A-1 Useful Service Sensor Tests ................................................................................... A-2 Sensor Listing ........................................................................................................... A-2

P RELIMINARIES

Solenoid Listing ....................................................................................................... A-4 Motor Listing ............................................................................................................ A-4

Volume 1 Chapter B Guide Technical Updates

Luxel System PCB Replacement .......................................................................... B-1 Laser Temperature and Humidity Control ....................................................... B-4
Operation................................................................................................................ B-4 Module Replacement ............................................................................................ B-5

Aperture Control Replacement ............................................................................ B-6

Preparation ............................................................................................................. B-6 Replacement Procedure ........................................................................................ B-6 Setting up Procedure ............................................................................................. B-7

Punch, Registration and Centerer (Fuji)............................................................. B-9

Punch Assembly Removal .................................................................................... B-9
Accessing the Assembly ...................................................................................... B-9 Removing the Assembly ...................................................................................... B-9 Complete Punch Replacement........................................................................... B-11 Punch Adjustments and Checks ........................................................................ B-11 Visual Plate Punch Check.............................................................................. B-12 Punch Checks ................................................................................................ B-12 Replacing the Punch Pins .................................................................................. B-12 Removing the Punch Motor............................................................................... B-13 Replacing the Chad Wipers ............................................................................... B-14

Vacuum and Air Control ..................................................................................... B-16

P RELIMINARIES

Volume-Chapt er

1-1

INTRODUCING THE LUXEL SYSTEM

This chapter introduces the main features and modules of the Luxel platesetter system:

1.1 Luxel CTP Features

The Luxel CTP belongs to the Fujifilm family of Luxel platesetters for scanning directly from computer-to-plate using photopolymer plates. It operates as a single- or dual-laser expose system with a range of three system variants and modules for loading plates up to a maximum size of B1 or B2: Fully-Automatic (B1 and B2): modules include - Autofeeder, Plate Transport Module, Imaging Engine, Buffer, Processor and Stacker - see Figure 1.2 and Figure 1.3. Fully-automatic systems are either with or without a punch. Semi-Automatic (B1 and B2): modules include - Imaging Engine (with loading platform), Buffer (B1 versions only), Processor and Stacker - see Figure 1.4. All Semi-automatic machines are without a punch (web). Manual (B1 and B2): modules include - Imaging Engine (with loading platform). All Manual machines are without a punch (web). A flow of job images is sent directly across a SCSI bus from the RIP and held in a queue on the Engine which serves as the main scanning module. While exposing images to plate, the Engine can continue to receive and store new jobs from the RIP. The Luxel CTP uses an internal drum with plate vacuum, plate punching (fullyautomatic only) and a high-speed spinner to scan media with modulated laser light. It processes RIPped data for fast optical scanning, controls plate handling to the output, and runs system software for managing all the main operations. Overall control of the machine is by the operator using an MMI touchpanel displaying sets of menu screens as icons and selectable button options.

4 4

Luxel CTP Features .................................................................................................... 1-1 Introducing the Luxel Modules ................................................................................. 1-3

VOLUME 1 (1-2) INTRODUCING T HE LUXEL SYSTEM

A typical Luxel CTP system has the following standard and optional features: A separate Raster Image Processor (RIP) server and optional client workstations. 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 system. 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 engineer.

1.1.1 Introducing the Luxel CTP Configuration

A typical site configuration, shown in Figure 1.1, would normally allow the RIP server to accept images from a number of networked desktop sources. Network links are: Ethernet: an example of a typical protocol between the RIP server and DTP systems. RS232: diagnostic data is sent from the main System PCB on the Engine to the PC for review by the engineer. SCSI: RIPed image data sent from the PC to the engine. RS232: communication link for controlling the flow of plates to the Processor.

L UXEL P LATESETTER VOLUME 1 (1-3)

RIP SOFTWARE ETHERNET

IMAGES FROM DESKTOP SYSTEMS

RIP SERVER *

MULTI-CASSETTE HOUSING

DIAGNOSTIC DATA

IMAGE DATA

ENGINE

BUFFER

PLATE PROCESSOR

AUTOFEEDER

PTM STACKER NOT SHOWN

* SEE YOUR RIP USER'S GUIDE

PROCESSOR COMMS

Figure 1.1 Typical Luxel CTP configuration: fully-automatic

1.2 Introducing the Luxel Modules

The platesetter equipment modules are shown in Figure 1.2. to Figure 1.5 with each variant module listed in Table 1.1.
Table 1.1 Main Luxel equipment modules B1 Variants Main Modules: Autofeeder: Trolley Cassette PTM Imaging Engine Buffer Fully-Auto Manual Semi-Auto Manual B2 Variants Semi-Auto Fully-Auto

a a a a a a

a a

a a

a a a a a a

VOLUME 1 (1-4) INTRODUCING T HE LUXEL SYSTEM

Table 1.1 Main Luxel equipment modules (Continued) PAT Processor

NOTE: the B1 and B2 semi- and manual machines can be upgraded to fully-automatic.

MULTI-CASSETTE HOUSING

SERVICE SIDE

BUFFER

AUTOFEEDER

PLATE TRANSPORT MODULE (PTM)

ENGINE

USER SIDE
PROCESSOR

Figure 1.2 Luxel 9600 CTP platesetter modules: B1 fully-automatic

MULTI-CASSETTE HOUSING

SERVICE SIDE

BUFFER

AUTOFEEDER

PLATE TRANSPORT MODULE (PTM)

ENGINE

USER SIDE
PROCESSOR

Figure 1.3 Luxel 6000 CTP platesetter modules: B2 fully-automatic

a a

a a

a a

a a

L UXEL P LATESETTER VOLUME 1 (1-5)

BUFFER

PROCESSOR

ENGINE LOADING PLATFORM

Figure 1.4 Luxel 9600 CTP platesetter modules: B1 semi-automatic

PROCESSOR

LOADING PLATFORM

ENGINE

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 systems 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 protected by a multi-cassette housing assembly.

1.2.1.2 Trolley and Cassette

See Figure 1.6. Cassettes are always transported on a trolley for loading and installing in the Autofeeder. Loading the cassette is carried out in a safelight area, usually separate from the platesetter room which operates under normal lighting conditions. Cassettes are never manually lifted by the operator or engineer. Each cassette has: an (ID)entity label read by the PTM a removeable top cover for plate loading a front lid that opens when the cassette is forwarded to the PTM feed head. Cassettes and trolleys require periodic maintenance.

CASSETTE

TROLLEY

Figure 1.6 Trolley and cassette: general view

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 safelight loading area to the Autofeeder cassette door where it docks into a set position. This allows the operator to push the cassette onto to an empty shelf.

L UXEL P LATESETTER VOLUME 1 (1-7)

1.2.2 Plate Transport Module (PTM)

The module consists of an interleaf bin and the plate handling mechanisms used to advance the cassette from the Autofeeder, and remove plates and interleaf paper from the cassette before the plate is conveyed to the drum. See Volume 2 Section 3.3 which describes the module in more detail.

1.2.2.1 Interleaf Bin

Interleaf paper between the plates is diverted to a waste bin area that is periodically emptied by the operator. System software keeps a count of the removed sheets and sends an alert to the MMI.

1.2.2.2 Plate Handling Mechanisms

A set of seven plate handling mechanisms inside the PTM carry out the following operations: secure the cassette to the shelf: X-direction door pull the cassette from the shelf to the feed head: cassette forward raise the plate pack to the correct height for plate nudging: stack increment nudge the plate and take it away from the pack: feed head prevent plate multi-feeds during the takeaway: retard pad divert and drive the interleaf sheet to a bin: interleaf diverter/drive guide and support the plate on route to the drum: plate guides.

1.2.2.3 Air Knife

An Air Knife system removes dust particles from the plate as it passes into the drum.

1.2.3 Imaging Engine

The Engine is responsible for receiving and storing job data from the RIP, processing image data for drum scanning (by deflecting and modulating two laser beams), driving the traverse carriage, managing the interlocks and generating the DC supply voltages for all other modules. It also houses the MMI (Man Machine Interface) console used by the operator to control production workflow. See Volume 2 Section 3.4 which describes the module in more detail.

1.2.3.1 Optics Base and Periscope

Laser image processing is carried out in the optics base that generates a single laser beam split into two separate beams and then recombined into two co-incidental beams. Laser beam processing includes operations and modules run from the optics base: generate a laser beam: laser module filter light beam intensity: neutral density (ND) filter deflect beams for spinner rotation: electro-optic deflector (EOD)

VOLUME 1 (1-8) INTRODUCING T HE LUXEL SYSTEM

detect beam misalignments: position detector (POD) correct focus for plate thickness: focus adjust adjust spot size on a plate: aperture (NA) control. Other optics operations and modules are: Optics motor control, laser current limits, temperature limits and image data drive: violet optics motor board (VBOMB). beam deflection drive control: electro-optic deflector drive board (EODD) A `periscope' arrangement, consisting of two mirrors, bends the beams from the optics base towards the spinner. An intervening assembly moves across the path of the beams detects their laser power. See Volume 2 Section 5.1 which describes the module in more detail.

1.2.3.2 Loading Platform

Manual and Semi-Automatic machines have a loading platform allowing the operator to manually load a single plate for each job. Two versions are available for B1 and B2 sized plates. See Volume 2 Section 3.4.2.1 which describes the module in more detail.

1.2.3.3 Traverse Carriage

A traverse carriage, housing the spinner and mirror, moves across a central beam and drive rail using a frictionless drive shaft and a ball cage. Local control from a traverse PCB reads the current position of the shaft, the spinner rotation rate (encoder) and drives the traverse motor. See Section Volume 2 Section 4.1 which describes the module in more detail.

1.2.3.4 Drum and Input/Output Modules

Two band roller modules on the drum input and output move the plate from the PTM to the drum, and from the drum to the Buffer. After the plate has dropped into the drum from the input side, a push bar moves it towards the punch where it is held in position for centering and punching. After scanning, the push bar moves the plate to the output module where it is conveyed to the Buffer.

1.2.3.5 RFI Box

A separate box, housed inside the Engine, generates the system DC voltages distributed to other modules, and contains the main system and optics control PCBs. See Volume 2 Section 6.4 which describes the module in more detail.

1.2.3.6 Man-Machine Interface (MMI) Console

An MMI console on the Engine displays a set of menu screens with icons and buttons that the operator selects to control the platesetter. MMI menus are described in the Luxel Platesetter Operator's Manual.

1.2.3.7 Purified Air System

Clean air from a PAT module passes into the engine and optics base to ensure positive air pressure.

L UXEL P LATESETTER VOLUME 1 (1-9)

1.2.3.8 Drum Vacuum System

Provides the vacuum for conforming plates to the drum and air blow for releasing the plate. See Volume 2 Section 7.1 which describes the system in more detail.

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.

1.2.5 Plate Processor

A Plate Processor is closely-coupled to the Engine output so that both units operate in daylight conditions. The Engine and Processor share the same communication (comms) protocol: as plates are sent to the Processor, the two machines pass commands, for instance, to check if the Processor is ready. Communications can be enabled or disabled from the MMI; for maximum production purposes the link is normally enabled. The Processor is supplied separately from the other platesetter equipment and has its own Service Guide.

1.2.6 Plate Stacker

An optional Stacker, shown in Figure 1.7, collects developed plates from the Processor and stacks them in an upright position for the next production stage. Unlike the Processor, the stacker operates independently using a sensor to detect the arrival of a plate. Power is supplied from the Processor. The Stacker (from Global Graphics) is supplied separately from the other platesetter equipment and has its own Service Guide.

Figure 1.7 Plate Stacker

VOLUME 1 (1-10) INTRODUCING T HE LUXEL SYSTEM

Volume-Chapt er

1-2

INTRODUCING LUXEL MODULES

This chapter introduces the main Luxel modules and variants, and briefly describes how they function and operate.

2.1 Luxel System - Modules and Variants

Section 2.2 shows the main platesetter modules and their operations. A functional view of the system is shown in Volume 2 Figure 9.1. Platesetter modules are broadly grouped into five functional sub-systems: Plate Handling - plate handling describes how plates are physically transported to the platesetter output. The main modules and assemblies are:

See Chapter 2.2 and Chapter 2.3 (Description) and Chapter 3.2 (Replacements). Image Exposing - image exposing explains how image data is processed and converted to laser data for scanning. The main modules are:

4 4 4 4

4 4 4

4 4 4 4 4

Luxel System - Modules and Variants ...................................................................... 2-1 Introducing Plate Handling ........................................................................................ 2-3 Introducing Traverse Scanning............................................................................... 2-10 Introducing Image Expose....................................................................................... 2-17 Introducing Luxel Power and Control .................................................................... 2-28

Plate Handling Motor PCBs (FHMBs 1 to 4) Motors. Sensors. Solenoids and relays.

Optics Base modules - laser diode (pen), neutral (ND) density filter, electrooptic deflector (EOD), focus adjust, EOD High Voltage (HV) module. Periscope. Laser power detector.

VOLUME 1 (2-2) INTRODUCING L UXEL M ODULES

See Chapter 2.5 (Description) and Chapter 3.4 (Replacements). Traverse Scanning - traverse scanning explains how the traverse carriage moves across the drum for plate scanning. The main modules and assemblies are:

See Chapter 2.4 (Description) and Chapter 3.3 (Replacements). System and Power Control - overall management of the platesetter is from the Luxel System PCB, housed in the RFI box. The main modules are described as:

See Chapter 2.6 (Description) and Chapter 3.5 (Replacements). Vacuum and Contamination Control - a set of modules that generate and control vacuum, drum blow and purifying air:

See Chapter 2.7 (Description).

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

Violet Boxer Optics Motors Board (VBOMB). Electro-optic deflector driver (EODD).

Spinner. Traverse PCB (STB). Traverse motor. Readhead and linear scale.

Luxel System Board (LSB). CAN Bus. PSU 1. AC/DC distribution. Interlocks and emergency stop control. Power Filter PCB.

PAT. Valve Cage Solenoids. Air Knife. Compressors (drum blow).

L UXEL P LATESETTER VOLUME 1 (2-3)

2.2 Introducing Plate Handling

Figure 2.1 and Figure 2.2 show a top-level view of the plate handling systems. Plate handling is a sequential set of machine operations for transporting plates, one at a time, between the variant plate loading system and the processor. It uses the following modules: Autofeeder (fully-automatic): houses cassettes (with plates) on elevator shelve(s) for feeding into the PTM. PTM (fully-automatic): feeds plates from a cassette to the engine and removes interleaf paper. Engine (all variants): holds a plate in a drum for centering, exposing and punching (if the punch is fitted). Buffer (fully-automatic): transports plates from the engine to the processor. Plate handling operations are carried out by plate transport mechanisms (rollers, push bars, etc) locally controlled by motors and sensor devices. Local management is from software routines running on a local FHMB PCB. Overall system management is from the LSB that sends commands (and receives data) to the FHMB.

PROCESSOR

SEMI-AUTOMATIC ONLY

7 CONVEY

BUFFER

PLATE

8 DEVELOP

IMAGE

6 SCAN
OUTPUT

PLATE

4 CHECK PLATE 1 LOAD

IS NOT SKEWED

INPUT

Figure 2.1 Plate handling modules (semi-automatic and manual)

PLATE

5 VAC PLATE

PUSH PLATE TO REG PINS

ENGINE

TO DRUM

AUTOFEEDER

PTM

ENGINE

BUFFER

PROCESSOR

CASSETTE ON SHELF CASSETTE OPENS INPUT OUTPUT

VOLUME 1 (2-4) INTRODUCING L UXEL M ODULES

NUDGE & TAKEAWAY PLATE

11 CONVEY
PLATE

12 DEVELOP
IMAGE

PUSH PLATE TO REG PINS

2 FORWARD
CASSETTE STACK

3 RAISE 5 REMOVE
INTERLEAF

6 7 CENTRE
PLATE

9 PUNCH

PLATE *

10 SCAN

PLATE

1 SELECT CASSETTE

Figure 2.2 Plate handling modules and operations (B1 fully-automatic)

8 VAC PLATE
TO DRUM

* IF PUNCH IS FITTED

L UXEL P LATESETTER VOLUME 1 (2-5)

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.

2.2.1 Plate Handling Board (FHMB)

Four plate handling motor PCBs are fitted on the platsetter: FHMB 2 and 3 fitted to the PTM FHMB 1 and 4 fitted to the Engine. Each FHMB operates using the same on-board functions and are replaced using the same procedure. Differences between PCBs depend on local I/O device connections for the variant machine and the on-board control firmware. A description of each FHMB interface to their devices is given in the following sections: FHMB 1 (Engine): see Volume 2 Section 3.4.1.1. FHMB 2 (PTM): see Volume 2 Section 3.3.1.1. FHMB 3 (PTM): see Volume 2 Section 3.3.1.2. FHMB 4 (Engine): see Volume 2 Section 3.4.1.2. Figure 2.3 and Figure 2.4 show all the sensor inputs and motor/solenoid drives for plate handling for the main platesetter variants.

VOLUME 1 (2-6) INTRODUCING L UXEL M ODULES

SENSOR INPUTS
INPUT MODULE (ENTRANCE/EXIT)

MOTOR/SOLENOID OUTPUTS
FRICTION BAND INPUT MODULE (DC)

FHMB (1)
PUNCH (DC) MIXER FAN DETECT ENGINE PUNCH MOTOR (ON/OFF) POSITION MIXER FAN (SOL) ALERT CONTROL (RELAY)

INTERLEAF DOOR OPEN CASSETTE IDS 15 CASSETTE FWD/REV LIMIT VECTOR DRIVE OVERLOAD/ALARM ELEVATOR SENSOR SHELF (1-3) ELEVATOR SENSOR (TOP/BOTTOM) CASSETTE AT NUDGER XDIRECTION DOOR (UP/DOWN) CASSETTE DOOR CLOSED (SCHMER) PLATE AT PRE-DIVERTER STACK HEIGHT (HOME/TOP) RETARD (UP/DOWN/MADE) PAPER TENSIONER PARK POSITION (PRE-INPUT) CASSETTE EMPTY NUDGER DETECT NUDGER LIMIT (UP/DOWN) PAPER POST DIVERTER (TOP/UNDER) INTERLEAF NIP CLEAR PLATE PAST DIVERTER REG MOTOR (IN/OUT) POSITION CENTERING (RH/LH) DETECT CENTERING HOME OUPUT MODULE (ENTRANCE/EXIT) PLATE IN PUNCH PUSH BAR FWD LIMIT/HOME BUFFER (ENTRANCE/EXIT) CHAD TRAY HOME FAST PHOTO DETECT SWING ROLLER (HOME/IN) REG PIN CONTINUITY (NON-PUNCH ONLY) ENGINE PTM PTM

CASSETTE FORWARD (DC) XDIRECTION DOOR (DC)

FHMB (2)

DOCKING LIGHT (SOL) ELEVATOR (SYNCH) ZDIRECTION CONTROL (DC) CASSETTE DOOR LOCK (SOL)

STACK HEIGHT (DC) NUDGER & TAKEAWAY (DC)

FHMB (3)

NUDGER LIFT (DC) 24 V FOR DISTRIBUTION BOARD INTERLEAVE DRIVE (DC) AIR KNIFE FAN (RELAY) RETARD DROP (STEP) DIVERTER (SOL)

PUSH BAR CARRIAGE (STEP) BUFFER FEED TO PROCESSOR (STEP)

FHMB (4)

CENTERING (STEP) REGISTRATION PINS (DC) VAC SOL (BV30, 40, 41) FRICTION BAND OUTPUT MODULE (DC) COMPRESSOR CONTROL DRUM VACUUM CONTROL SWING ROLLER (DC) (NON-PUNCH ONLY)

Figure 2.3 FHMB Input/output devices (B1 and B2 fully-automatic)

L UXEL P LATESETTER VOLUME 1 (2-7)

SENSOR INPUTS
INPUT MODULE (ENTRANCE/EXIT)

MOTOR/SOLENOID OUTPUTS
FRICTION BAND INPUT MODULE (DC)

FHMB (1)
PLATE LOAD PUSH (HOME) MIXER FAN DETECT PLATE LOAD CENTERING PUNCH MOTOR (ON/OFF) POSITION ENGINE MIXER FAN (SOL) PLATE LOAD CENTRE/PUSH (STEP) FRICTION BAND INPUT (DC) ALERT CONTROL (RELAY)

REG MOTOR (IN/OUT) POSITION CENTERING (RH/LH) DETECT CENTERING HOME OUTPUT MODULE (ENTRANCE/EXIT) PUSH BAR FWD LIMIT/HOME BUFFER (ENTRANCE/EXIT) (SEMI ONLY) FAST PHOTO DETECT SWING ROLLER (HOME/IN) REG PIN CONTINUITY ENGINE

PUSH BAR CARRIAGE (STEP) BUFFER FEED TO PROC (STEP) (SEMI ONLY)

FHMB (4)

CENTERING (STEP) REGISTRATION PINS (DC) VAC SOL (BV30, 40, 41) FRICTION BAND OUTPUT MODULE (DC) COMPRESSOR CONTROL DRUM VACUUM CONTROL SWING ROLLER (DC)

Figure 2.4 FHMB input/output devices (semi-auto and manual)

2.2.1.1 FHMB Operation

A block view of the PCB is shown in Figure 2.5. This section describes the main common functions on FHMBs (1 to 4). Each FHMB operates as a local node under the system management of the LSB that sends and receives high-level media handling commands and status messages. Plate handling control is distributed across the CAN bus and effectively operates in real-time. It allows devices (sensors, motors, solenoids, relays and fans) to switch on/off in the required sequence for moving plates to the processor or output. FHMB functions are summarised as: Interfacing for sensors connected directly or indirectly (via distribution boards). Control of motor drives associated with each sensor. Control of local solenoids to various devices (relays, etc). interconnect PCBs for the CAN bus network. All four PCBs are identical in build, but the tasks they perform depends on the devices they control. Because the handling software routines are configured for each device, it is not possible to interchange FHMBs. Service engineers can check the configuration (software issue levels, etc) from a separate utility, or

VOLUME 1 (2-8) INTRODUCING L UXEL M ODULES

dump and restore configuration parameters to a local hard disk. On-board NVRAM values for plate handling can also be accessed and stored to the engine disk.

SOLENOID to DRIVERS SOL 5

STEPPER MOTOR DRIVERS

UMBILICAL (CAN OUT AND STB POWER +24V/+36V)

SOLENOID CONTROL

STEPPER MOTOR CONTROL

DC MOTOR CONTROL

DC MOTOR DRIVERS

MPU MEMORY

CAN BUS

CAN TX/RX

MPU

A TO D

RS232

CAN IN (1 & 2)

+24V (FHMB 1 TO 4)

+36V (FHMB 4 ONLY)

Figure 2.5 FHMB operation - block view

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) B) C)

motors on/off and move a set distance sensors on/off solenoids on/off.

SENSORS

SENSOR I/F

to S27

S0

SENSOR REGISTER

SENSOR PULSING & SYNCH.

+5V REG

PCB DEVICES AND EXTERNAL SENSORS

FHMB PCB

SOL 0

SM 0

to SM 3

DC 0

to DC 2

L UXEL P LATESETTER VOLUME 1 (2-9)

The CAN bus interconnections for the FHMBs (and STB) is based on the daisychain 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) B) C) D)

one fuse for each stepper and dc motor one fuse for each high-power solenoid one fuse to cover all the low-power solenoids 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 clocking 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 stepper 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

2.3 Introducing Traverse Scanning

The traverse scan system is managed by the LSB using position data passed from the Traverse system. Its main assemblies are housed on a traverse beam and a traverse carriage. A cast aluminium beam supports the traverse carriage and includes the following sub-assemblies: V-groove rail: provides a sliding surface for the ball cage. Ball cage: a precision assembly of ball bearings that allow the carriage to slide along the V-groove. Both carriage and cage need to be physically aligned. A separate software utility checks for `creep' (that is, the two assemblies gradually become misaligned as the system constantly traverses) Drive rail: provides a drive rail for the traverse motor spindle and a base for the linear scale. Linear scale: runs along the drive rail to provide position coding for the readhead encoder. Actuators: All position measurements are offset from two actuators that indicate the exact reference (Index) and coarse reference (Home). The carriage assembly is motor-driven to run along the beam drive rail from its Home position on the Service side. A traverse motor, which moves the carriage, is controlled directly from the Traverse PCB. Position feedback is provided by a readhead sensing micro positions on the linear scale; commands from the System Board, via the Traverse PCB, control the position and direction of the carriage. Traverse PCB: This PCB runs local software handling routines for operating the traverse carriage mechanisms. Spinner: The spinner (Speedring type) includes an encoder that returns an Index signal for each revolution and a rotating mirror for reflecting the laser beams onto the plate. Baffles: two baffles are fitted: removable and fixed. Traverse Motor: a DC motor drives a spindle along the drive rail. The motor assembly includes a casting. Readhead: an encoder with sensors for reading the micro positions on the linear rail. Umbilical: An umbilical ribbon cable from the Traverse PCB to FHMB4 connects the CAN control/status signals and the power voltages. The cable is positioned along a tray and flexes as the carriage traverses the drum. The carriage is removed from the engine using two extenders fitted to the beam. Most service procedures are completed while the carriage is located on the extenders. Main Diagnostic tests and utilities are available for the Service Engineer to check and move the traverse.

L UXEL P LATESETTER VOLUME 1 (2-11)

2.3.1 Traverse Board (STB)

See Figure 2.6. The Traverse PCB controls the spinner and traverse mechanisms, and also provides the drive currents for the spinner and traverse motors. The main functions located on this PCB are described below. Refer to Section 2.3 for more information on how the Traverse PCB operates as part of the media scanning subsystem.
TRAVERSE MOTOR READHEAD ENCODER SCALE POSITION SIGNALS/TRAV INDEX/HOME DCDC +36V +24V STB

HALL SENSE

SPINNER/ ENCODER

+36V 3-PH DRIVE

OUTPUT DRIVE (AND COMMUTATION)

REF CLK

SPIN INDEX

19.2 MHz

DATA A

SPINNER CONTROLLER

13.6 MHz

480 KHz

ENABLE

MPU

TRAV INDEX/ HOME EDGE DETECT RS232 +5 V 5 V

MEMORY

TO SSB (VIA FHMB4)

Figure 2.6 Traverse PCB - block view

TO SSB (VIA FHMB4)

CAN BUS

PRECISION MOTOR CONTROLLER

LOCK/ FAULT

DAC

OUTPUT DRIVE

DC

VOLUME 1 (2-12) INTRODUCING L UXEL M ODULES

2.3.1.1 STB Main Functions

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 Board over the CAN bus. These commands typically include, for example, Spinner Start/Stop, Traverse Datum, Fans On/ Off. Initialise 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.

Precision Motion Controller

See Figure 2.7. An LM628 Precision Motion (PM) Controller, operating in position mode, is dedicated to controlling the traverse servo mechanism. The device provides multiplexed 6-bit position data to a 12-bit D-to-A controller that drives the DC traverse motor. The PM controller is programmed with position, velocity and acceleration parameters appropriate for the image size, number of optical beams and resolution. Two values to the PM controller are compared to give a digital error signal that is converted to a drive voltage. PLL reference frequency at 13.62 MHz divided down into two different clock frequencies (4.55 and 6.82 MHz), depending on the resolution and number of beams. Digital encoded signals from the readhead. The drive signal is produced by comparing two sets of numerical values:

A digital error signal is then developed as a numerical value that is passed to the DAC for driving the motor. When error or limit conditions are detected, the PM controller is also able to interrupt the MPU.

4 4

The desired position trajectory (in microns depending on the optical speed) calculated by the PM controller. Feedback of incremental position pulses from the linear encoder to an accumulator in the PM controller.

L UXEL P LATESETTER VOLUME 1 (2-13)

COMPENSATION CIRCUIT

AMP

DC

TRAVERSE MOTOR PM CONTROLLER LINEAR POSITION ENCODED SIGNALS READHEAD

DIFF CALCULATEED POSITIONS

DAC

REF GENERATOR

4.5/ 6.8MHz

REF CLK 19.2MHz

FREQ SEL

13.6 MHz

Figure 2.7 Traverse position control

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 position data.

MPU

PLL

TRAVERSE MONITOR

DIVIDER

SUM REGISTER

CURRENT POSITIONS

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REF FREQ (480 Khz)

TP11

TP9

PHASE DETECTOR

ANALOGUE SERVO

PULSE WIDTH MODULATOR

PAL LOGIC

DATA A

SENSE +36 V

TP9 OUTPUT

SPINNER 3-PHASE

POWER OUTPUT

166 microseconds

+36 V

TP11 OUTPUT DEMAND ON STARTUP RUNNING DEMAND LOWER SWITCHES CLOSED FOR BRAKE ON MOTOR WINDINGS

Figure 2.8 Spinner speed control circuit

Spinner controller circuitry on the Traverse PCB is composed of five separate functions detailed below.
1: Phase Detector.

The phase detector compares the phase and frequency of DATA A from the encoder with a reference frequency of 480 KHz (or 160 KHz when the spinner is idling at 10, 000 rpm). This allows any deviations of spinner speed to be determined. An analogue servo, consisting of an integrator and a phase advance circuit, ensures that the spinner is phase-locked to the reference signal (that is, DATA A and reference edges are co-incident). A filter sets the overall bandwidth of the control loop.

2: Analogue Servo.

3: Pulse Width Modulator. This function turns the analogue servo signal into a 60 KHz pulse train with a duty cycle proportional to the analogue signal level. This signal has an offset, so 5 V represents 0% and 10 V represents 100%. 4: PAL.

A PAL logic stage uses the PWM signal to drive the spinner motor with a power level proportional to the level demanded by the analogue servo stage. It also sequences the power stage outputs (3-phase) so that the spinner motor is driven correctly. The logic stage handles control functions, for example, checking that the spinner speed is within normal limits.

L UXEL P LATESETTER VOLUME 1 (2-15)

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 spinner 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 diagnostics 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 onboard 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 pushpull 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.

2.3.2 Cassette and Media Database Control

See the Luxel Platesetter Operator's Manual and also Figure 2.9. A hard disk (HDD) on the Engine stores downloaded job images for scanning, persistent images for plate quality tests, and holds the following MMI database information: Media: media details (plate size/thickness, type), including the default number of plates for a pack. This database is downloaded from the RIP. The

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number of plates is an editable value. Cassette: the cassette ID is identified on the database when it is pulled into the PTM. Each cassette holds details of the loaded media type selected by the operator from the MMI. Elevator: holds the cassette ID only and is updated when the cassette is added or removed.
ID#3 ID #3 #4 #7 SELECT ID#3 MMI SELECT TYPE & QTY ACTIVE CASSETTE ID#3 DATABASE ON DISK MEDIA TYPES ON RIP IMAGING ENGINE JOB IMAGE DATA MEDIA TYPE LP-NV 1030 LP-NV 745 LP-NV 724 QTY 12 40 60

AUTOFEEDER

PLATE TRANSPORT

RIP INTERFACE

Figure 2.9 Cassette and media database operation

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.

2.3.3 Plate Processor Interface Commands

The Processor and Engine use a common set of interface commands to communicate information on machine status and readiness across an RS232 bus while the system is running. This communications link is enabled or disabled from the TOOLS menu on the MMI (see the Luxel Platesetter Operator's Manual.)

L UXEL P LATESETTER VOLUME 1 (2-17)

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 enabled, 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.

2.4 Introducing Image Expose

Image expose system (data flow and control) functions are shown in Figure 2.10. Job image data is downloaded from the RIP server, stored as a queue on the engine hard drive disk (HDD) and processed into optical streams (X and Y) for exposure on a plate. Once the engine has stored a complete image (at least one separation) from the RIP, it is held in a queue for plate exposure. The plate size and type is selected by the platesetter from the RIP job details. Laser beams X and Y are generated, focused, adjusted for density and checked for correct alignment and power settings from the optics base.

2.4.1 Image Expose Modules and Operations

Image exposure is generated and controlled by the following: RIP - two-way communication between the RIP server and the platesetter is via a differential SCSI link to the LSB. A diagnostics RS232 channel allows the engineer to interrogate the results of embedded test routines on the LSB. Luxel System Board - the System Board is overall imaging manager that controls the expose sequence via the CAN bus. It receives image data from the RIP, stores it onto engine HDD and converts it into two streams for the X and Y beams. Electro-optic deflection is based on data supplied by the LSB. VBOMB - the Violet Optical Motor Board controls the optics motors on the optics base for the ND density, focus adjust, aperture control and laser power detection. Control is monitored from the sensor signals returned by these devices. The VBOMB also controls the laser diode temperature, provides power limit protection and the current control for image data switching. Volume 2 Section 5.17 describes the operation of the VBOMB in more detail. EODD - the Electro-Optic Deflector Driver board generates the sine and cosine waveforms for the EOD deflectors from data supplied across the EODD interface bus from the LSB. Waveforms are passed to the EODHV board for further amplification. EODHV - the Electro-Optic Deflector High Voltage board takes the sine and cosine waveforms from the EODD and converts them into high voltage signals suitable for the Electro-Optic deflectors (EODs). It also allows a DC bias to be applied to the deflectors to allow beam coincidence to be achieved. Optics Base - this consists of modules that generate the two laser beams,

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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 M2 STB CAN

TO LUXEL SYSTEM BOARD

LPD VBOMB M1 PERISCOPE

TO DRUM SURFACE POSITION DETECTOR (POD) ND WEDGE FILTER

APERTURE

FOCUS

VBOMB OPTICS BASE LASER (X)

VBOMB EOD (X)

VBOMB

BEAM COMBINER

LASER (Y)

EOD (Y) TRANSFORMERS X/Y

PD AND LD PCB

IMAGE DATA & CONTROL

PD AND LD PCB DRIVE/POWER CONTROL

EODHV

APERTURE FOCUS POD ND TEMPERATURE/ HUMIDITY SENSOR BOARD

LPD

VBOMB

EODD

CAN CAN

IMAGE DATA CONTROL

STB

LUXEL SYSTEM BOARD

RFI BOX IMAGE DATA SCSI DIAGNOSTICS (RS232)

RIP SERVER

Figure 2.10 Platesetter system: image data flow and control

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2.4.2 Image Data and Optical Path

Data for each image is compressed, stored, decompressed and converted to a serial stream on the LSB and passed to the laser module as a switched data stream, see Figure 2.13. Two laser sources (LD1 and LD3) generate respective polarised beams (X or and Y). deflected for position by an electro-optic device (EOD). The two beams, when combined, run directly on the same axis, appear visually as a single beam. Each beam provides a range of focused spot sizes for high speed scanning and productivity. Resolutions available (at l/mm) are: 47, 48, 71, 72, 94, 96, 100 and 144.
LASER IMAGE DATA/EOD DATA M1 MIRROR (FACTORY ADJUSTED ONLY)

VBOMB (OPTICS MOTOR CONTROL)

OPTICS BASE LASER POWER DETECTOR COLLIMATING LENS (L5) PERISCOPE

SPINNER

L6

COLLIMATED LASER BEAMSALONG DRUM AXIS LASER BEAMS FOCUSSED AT DRUM SURFACE

M2 MIRROR (FIELD ADJUSTABLE)

Figure 2.11 Media expose system - main modules

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)

DRUM

OPTICS BASE

X Z X Z

SPINNER ROTATION

BEAM DIRECTION SCAN DIRECTION

Y USER END

Figure 2.12 Optical beam axis around drum

See Figure 2.13. An optics base, located on the rear of the engine (user side), generates and modulates two laser beams split into X and Y data channels.
1. X Channel: when viewing the optics base, the X beam is the upper light path.

Deflection is in the horizontal plane when the beam exits the optics base just before M1. in the vertical plane when the beam exits the optics base.

2. Y Channel: the Y beam is the lower light path in the optics base. Deflection is

VOLUME 1 (2-22) INTRODUCING L UXEL M ODULES

30 mW O/P POWER

DRIVE CURRENT (SWITCHED BY IMAGE DATA)

BIAS CURRENT IMAGE DATA FLOW

A)

IMAGE DATA

FEEDBACK

BIAS AND DRIVE CURRENT

B)

ONE FULL SPINNER REVOLUTION

Figure 2.13 Image data and current levels

2.4.3 Optics Base Module Control

Optics control for imaging is set from the: VBOMB (see Volume 1 Section 2.4.3.1) EODD (see Volume 1 Section 2.4.3.2).

2.4.3.1 Optical Motor Control (VBOMB)

See Figure 2.14. The VBOMB controls the motor drives to the optics base motors based on signals received from local sensors, indicating Home and Limit positions, and the LSB. As a CAN node it operates under the supervision of the System Board.

L UXEL P LATESETTER VOLUME 1 (2-23)

EXTERNAL MODULES

LASER DIODE

POD I/F

LPD I/F

LASER I/F

VOLTAGES AND DRIVES

CAN CONTROL I/F

MOTOR DRIVERS

SENSOR I/F

TEMP AND LASER CONTROL

MPU

CAN

+5V

WEDGE FOCUS APERTURE POD LPD

LIMIT/ HOME SENSORS

+/-15V +24V

Figure 2.14 VBOMB - block view

VBOMB functions are summarised as: Provides bias and data level current for image data switching. Receives and interprets commands from the LSB across the CAN bus. Drives four low-power stepper motors for the following:
A) B) C) D)

ND Filter wheel Focus adjustment Aperture (beam converter) Laser power detection.

OPTICS BASE

LSB IMAGE DATA

LSB

DATA I/F

LASER I/F

LASER DIODE

POD

LPD

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Monitors sensor inputs for accurate motor positioning. Provides memory storage for local optics operation and set-up information. Controls and protects laser diode temperature and power limits. Optics devices (ND, focus, aperture and LPD) are moved by stepper motors to their Home position and a set number of steps in either direction from Home. Sensors associated with the devices are: ND Filter Home (S1) Focus Limit/Home (S2 and S3) Aperture Control Home (S5) Laser Power Detector Home (S6) Three detector PCBs are controlled from the VBOMB:
1.

Position Detector (POD): a two dimensional position detector that is used to measure the relative alignment of the laser beams. This detector is calibrated in conjunction with the ND wheel to obtain the optimum level of light power. Laser Power Detector (LPD): used as a reference for setting the output drive level. The LPD is calibrated to ensure that the laser beam is aligned with the centre of the detector.

2.

CAN Control Interface:

Real-time CAN signals are received and transmitted from a transceiver. CAN power (+5 VDC) is supplied to the VBOMB from the CAN connector.

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 diagnostics. New firmware code is downloaded from the RIP server via the System Board.

Voltages and Drives:

The supplied voltages, +24 VDC (drives stepper motors), +5 VDC (digital devices) and +15 V (drives lasers), are monitored by the MPU for providing environment information.

L UXEL P LATESETTER VOLUME 1 (2-25)

Laser Power Detector

Power levels for each beam are measured from the LPD.

Position Detector
The two beams are aligned by the VBOMB (from POD data) to be co-incidental during the non-scanning stage.

Motor Drivers
Low power (unipolar) stepper motors are driven from separate drivers controlled by the Timer Processor Unit (TPU) channel levels on the MPU.

2.4.3.2 EOD Control

Calibrated media expose control is based on a set of co-operating functions that operate before and during an expose scan: EOD deflection: deflects X and Y beams before they reach the rotating spinner mirror. Laser module monitoring: the module returns data on the current laser power and temperature outputs which are digitised and passed to the VBOMB. Beam coincidence alignment: beams X and Y are aligned, one on top of the other, for beam coincidence on the drum.

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 differential control voltage that consists, for each deflector, of a 667 Hz AC component 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 separated 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 transformer primary using the AC component recovered from the filter. The AC voltage 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 EODX0 VDC 1 kV PK-PK (ANTIPHASE)

-500 VAC

+1850 VAC ACROSS EODX INPUT +850 VDC

150 VAC

Figure 2.15 EOD drive voltage

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.

+24V DC BIAS +24V GND +12V AC MODULATION -1 VIOL

DC - DC

HT+ PUSH-PULL AMP (PART OF) BK

Figure 2.16
FILTER X OR Y DATA (AC + DC) HV STATUS HT+ DC BIAS EODHV PCB (ONE CHAN ONLY) +1 YEL PUSH-PULL AMP (PART OF) BN

EOD DATA

BLUE TO EOD (X OR Y) WHITE

EODHV (X or Y channel) - block view

EODD

L UXEL P LATESETTER VOLUME 1 (2-27)

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2.5 Introducing Luxel Power and Control

2.5.1 Luxel System Board (LSB)
See Volume 2 Section 6.1. The LSB acts as the overall manager of the system and performs the top-level control and processing tasks using resident firmware that is down-loadable. Some of the main functions and features of the LSB are: an interface to image data from the RIP server motherboard control for beam dongle facility provides the drive and iconic translation for the MMI display I/O connection to external modules (Processor, CAN node boards and RIP server) image data store and processing before exposure holds the deflection LUTs and NVRAM parameters used for dynamic EOD deflection control provides system control for the plate handling and optics motors. Platesetter system control and inter-node communications is across a CAN (Controller Area Network) bus that can also operate with the LSB as the master node. A description of this network (adapted for Luxel) is in Section 2.5.2. Functions on the System PCB are divided into two working areas: LSB System Control (see Section 2.5.1.1) LSB Image Data Path (see Section 2.5.1.2).

2.5.1.1 LSB System Control

See Figure 2.17. System control, based on the MPU (Motorola 68376), acts as an intelligent supervisor for the Luxel system to receive high level commands from the CAN network and transmit commands for driving the other electronic sub-systems. Overall control is based on the the bussing, interface and MPU arrangement shown in Figure 2.17.

L UXEL P LATESETTER VOLUME 1 (2-29)

CAN BUS (TO SOMB/FHMB)

RTC

MBUS I/F

MPU

PCI I/F (BRIDGE)

TO CONTROL CONSOLE

MMI I/F

TO INTERLOCKS

INTERLOCKS I/F

DIAGNOSTICS

PROCESSOR

Figure 2.17 System Board control functions

FLASH and SRAM Memory

Application, boot and diagnostic code files for the MPU are stored in (non-volatile) FLASH memory before transfer to the MPU on power-up or user request. Two MBytes of FLASH PROM (512 Kbyte devices) are fitted as standard, with provision for a further 1 MByte at a later stage. The contents of the FLASH memory can be updated at any time from a utility running on the RIP server. This facility is used for on-site software and configuration updates. The firmware level on the LSB must match the other node PCB firmware levels for the system to operate correctly. SRAM (512 Kbytes devices) is used (alongside FLASH memory) to provide writable storage for the MPU.

S/W DEBUG

RS232 SERIAL CONTROLLER

TO AOMD MODULE

CPU BUS

AOMD I/F

DATA CONTROL

FLASH/ SRAM MEMORY

TEMP IC

DATA CONTROL

LBUS I/F

VOLUME 1 (2-30) INTRODUCING L UXEL M ODULES

LSB Temperature Monitoring

The LSB monitors its own temperature and generates an in-range or out-ofrange signal from a dedicated thermostat on-board device. Temperature status signals are periodically read by the LSB which stops scanning and reports a failure to the MMI as an error code if the reading is out-of-range.

Voltages and Drives

The LSB operates with the following voltages supplied from the PSU: +5 V - used by digital and analogue devices. +15 V - used by the PLL and regulated down to +12 V for use by the disk drives.

LSB Diagnostics
The MPU is able to run a set of on-board checks for the memory and registers from commands and on power up.

Real-Time Clock
An embedded R-T clock is used by the system for date and time stamping. The clock is set from an engineering utility.

NVRAM
NVRAM on the LSB stores the system-specific parameters for controlling the optics, plate handling, etc. Volume 2 Section 1.8 explains how to view and temporarily store the parameters.

2.5.1.2 LSB Image Data Path

Figure 2.18 shows the image data route and functions on the LSB from the RIP image data input to the laser modulator.

Data Path Operation

See Figure 2.18. The basic sequence for processing image data by the LSB is as follows:
1. 2.

An image file (page/picture) is sent from the RIP via the PCI SCSI link. Data is transferred, via the PCI bus, to a compression circuit in consecutive 16-bit wide words. Direct memory access (DMA) and a first-in first-out (FIFO) buffer provide optimum transfer rates. Compressed data is transferred to a buffer memory in consecutive words using DMA/FIFO. From here, image data is stored to the SCSI disk. Steps 2. to 3. are repeated until a the complete image is received. When an image is to be exposed, the SCSI bandwidth is allocated on a priority basis to the output process. Steps 2. to 3. are reversed. Data is taken off the image storage disk, decompressed, and transferred to the output formatter/serializer by the DMA and FIFO buffer. The serializer synchronises data to an absolute position on the drum, and passes data to the EODD.

3. 4. 5. 6.

7.

The data path is capable of receiving image data from the RIP while transferring

TO SSB SYSTEM CONTROL

LBUS I/F TO SSB SYSTEM CONTROL LBUS

data to the optics system.

MBUS I/F MBUS

RIP IMAGE DATA DMA/ FIFO MBUS MBUS BUFFER MEMORY DMA/ FIFO MBUS INTERNAL SCSI I/F

Figure 2.18 System Board data path

DECOMPRESSION PATTERN GENERATOR DATA A (FROM STB) PIXEL CLK GEN

PCI/ SCSI

DMA/FIFO PCI BRIDGE

DATA COMPRESSION

OUTPUT FORMATTER

SERIALISER

L UXEL P LATESETTER VOLUME 1 (2-31)

DISK DRIVES

TO EODD

SCSI

SPIN INDEX (FROM STB)

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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 buffers.
1.

A compression (C-FIFO) input on the DMA controller interfaces to the compressor and accepts data at its the maximum rate while space exists in the FIFO. The input data pat is 32-bits wide. 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. 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.

2.

3.

The length of the compressed record depends on a calculated setting for multiples of input data lines. This calculation is also used by the decompressing process. 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 compression/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 decompressor 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.

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Serialiser
The serialiser takes the two beam streams from the output decompression buffers 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.

2.5.2 CAN Network Control

See Figure 2.19. System control messages are exchanged over an industry-standard CAN (Controller Area Network) bus distributed between the seven slave node PCBs: System (SSB) - this operates as a master to download embedded firmware to the other slave nodes. FHMBs (1, 2, 3 and 4) Traverse (STB) VBOMB. CAN network bussing is based on interlinking cables, daisy-chained between boards. Each board is linked to the network as a node that can transmit or receive messages to any other node. The CAN standard is a serial data interface used for real-time control signals where the machine environment calls for robust and reliable internal communications. The CAN network model for data transfer is especially useful in that nodes can be added, swapped or removed after the network mapping tables have been modified. Also, it provides a system with extra network management features and extensive real-time error checking and recovery procedures. On a CAN network, system data (sensor data, motor commands, etc) is passed between nodes as a frame messaging system where the signal content is labelled by an identifier that is unique throughout the network. All nodes receive transmitted messages and perform an acceptance test to detect whether the message is relevant. The message frame typically consists of fields denoting Start/End of Frame, Data, Control, Acknowledgements and CRC Error Bits. Other frames, controlling the network for bus errors and overloads, are also transmitted between nodes. Typical messages between the SSB and node boards would include, for instance, an SSB supervisor command to start a motor and a node response that the motor has started or failed to start after a timeout. Error handling routines, built into the CAN software, automatically attempt a recovery procedure depending on the type of error reported. All messages on the bus are checked by each node and acknowledged if they are correct. Bus errors will cause the frame to be retransmitted, or (in the case of persistent failures) for error reporting to the system user via the diagnostics.

VOLUME 1 (2-34) INTRODUCING L UXEL M ODULES

LSB

CAN2

FHMB(1)

CAN3

FHMB(2)

CAN1

CAN4

VBOMB

FHMB(3)

CAN5

TRAVERSE

UMBILICAL CAN

FHMB(4)

Figure 2.19 CAN node interconnection - (B1 and B2 fully-automatic)

LSB

CAN2

FHMB(1)

CAN_FHMB1_4

CAN1

VBOMB

TRAVERSE

UMBILICAL CAN

FHMB(4)

Figure 2.20 CAN node interconnection - (manual and semi-automatic)

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)

2.5.3 Power Distribution Control

See Figure 2.21 and Volume 2 Section 6.2. Platesetter power is generated and routed as follows: PSU 1: supplies +5 V, +24 V, +36 V, +15 and -15 V from the RFI box Power Filter: filters DC supply before it is routed from the RFI box. Vacuum Pump: AC mains is controlled via a relay so that vacuum is switched on during imaging. Emergency Power Stop: a separate PSU supplies +24 V to emergency buttons on the PTM (Fully-automatic) and Engine (manual). Interlock Control: the main voltages for the spinner, laser and plate handling motors are switched off by an interlock system operated by opening a cover. PAT, Stacker and Processor: these modules are powered separately from the Engine. Elevator: AC power is routed via the PTM for the elevator motor.

VAC PUMP INVERTER AC ENG_FHMBPWR DC x2 DC PWR3_INT DC FHMB3 INT_EMERG FHMB2 FHMB1 COMPRESSOR BOX

PUMP AC

AC

ELEV MOTOR

AC

AC

CTRL DC

VOLUME 1 (2-36) INTRODUCING L UXEL M ODULES

INTERLOCK BOX VACUUM

MAINS_DIST

AC

AC MAINS_RFI_IN

PWR2 DC CTRL FOR LASER

FHMB4

IEC DC DIST LSB +15V/-15V VBOMB ENG_INT

RFI BOX

AUTOFEEDER

24V_ENG

I/LOCKS (x4)

I/LOCK (x1)

I/LOCK (x1)

Figure 2.21 System power distribution and control (B1 and B2 fully-automatic)
ENGINE PTM

EXT I/LOCK

ENG_INT

BUFFER

Volume-Chapt er

1-3

SERVICING SAFETY PRACTICE

This chapter MUST be read before starting work on a service procedure for the automatic, semiautomatic and manual platesetters:

3.1

3.1.1 Warnings and Cautions

There are two types of safety notices in this Guide:

4 4 4 4 4 4

Health and Safety at Work (All Variants) .................................................................. 3-1 Laser Safety ................................................................................................................ 3-2 Safety Interlocks (All Variants)................................................................................ 3-19 Emergency Stop Circuit ........................................................................................... 3-22 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 Manual. Safety information in this chapter is for all three variants (Automatic, SemiAutomatic and Manual) platesetters.

Health and Safety at Work (All Variants)

This section applies to the Automatic, Semi-Automatic and Manual variants. All personnel are advised to familiarise themselves with any local or national legislation relating to health and safety at work. Particular attention should be given to those sections covering personal responsibility regarding safe working practices which must be strictly observed at all times. This chapter explains the safety conventions used in this manual and highlights safety practices specific to the product.

VOLUME 1 (3-2) S ERVICING S AFETY P RACTICE

1.

WARNINGS

are displayed for conditions which may endanger life.

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 equipment or materials.

CAUTION: The instructions given in cautions must be followed to avoid damage to equipment or materials.

3.1.2 Clothing and Jewellery

Do not wear clothing or jewellery which could be hazardous when in contact with any part of the equipment, or which could reflect laser light into an eye.

3.1.3 Equipment and Tools

Use the approved service tools, listed in Volume 3 Section 1.1, and wear the protective garments which are specified in this Guide.

3.1.4 Site Safety Rules

Most accidents can be avoided if you follow these simple rules. Familiarize yourself with the location of mains supply On/Off switch on the Engine, the two emergency cut-off switches on the PTM, the wall-mounted On/Off isolator switch and all other equipment switches. Always obey the warnings, cautions, and any other instructions included in this Guide, and in other relevant equipment manuals associated to the equipment. Never attempt to perform procedures that are not included in this Guide.

3.2 Laser Safety

This section applies to the Automatic, Semi-Automatic and Manual variants.
CAUTION: Use of controls or adjustments, or performance of procedures other than those specified herein, may result in hazardous radiation exposure.

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.

3.2.1 Manual Shutter Control

A manually-operated safety shutter is fitted on the periscope assembly (laser power detector) and is closed to prevent laser beams entering the drum. See Figure 3.1 below on how to open and close the shutter.

L UXEL P LATESETTER VOLUME 1 (3-3)

Laser radiation when open

AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

DANGER

OPEN

CLOSED

LASER POWER DETECTOR ASSEMBLY

SHUTTER

Figure 3.1 Manual laser safety shutter

3.2.2 General Laser Warnings

Laser light, because of its special properties, poses safety hazards not associated with other light sources. The use of lasers requires that all service engineers and everybody near the laser system, are aware of the dangers involved. Laser safety depends on the engineer being familiar with the instrument and the properties of coherent, intense beams of light. Laser beams can ignite volatile substances, such as alcohol or other solvents and damage light-sensitive elements in, for instance, photodiodes. Reflected beams can also cause damage. Note the following laser radiation warnings:
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.

3.2.3 Safety Warnings

Laser safety warnings must at all times comply with local and national regulations. While the laser is being serviced, it may be necessary to operate the platesetter with certain covers removed and the safety interlocks over-ridden using the approved method shown in Volume 3 Section 1.2. Under these circumstances, only the service engineer shall be in the Designated Laser Area (DLA). The DLA may be a room, a curtained area, or a purpose-built DLA tent.

3.2.3.1 A DLA Room

All other personnel should be warned of the hazard by: A laser warning notice attached to the door(s) leading to the room. An example is shown in Figure 3.2. A red warning light, positioned above the door(s) leading to the room, illuminated whenever there is a laser radiation hazard, see Volume 2 Section 6.7.

L UXEL P LATESETTER VOLUME 1 (3-5)

LASER CLASS 3B OPERATIONS WHEN WARNING LIGHT IS ON

LASER CLASS IIIb OPERATIONS WHEN WARNING LIGHT IS ON NO ENTRY TO UNAUTHORISED PERSONNEL

NO ENTRY TO UNAUTHORISED PERSONNEL

EUROPEAN U.S.A.

Figure 3.2 Typical laser warning signs

3.2.3.2 A DLA Curtain

Local legislation may permit the following alternative: Isolation of the platesetter by means of a curtain. The curtain must be opaque to violet light (405 nm) and must extend from floor to a height of at least 2.1 m (82.7 in). Warnings placed, where required, to ensure that personnel are aware of the laser radiation hazard inside the curtained area. Safety Notices and Hazards Safety labels are fitted to the equipment to warn you of potential hazards. These labels must not be defaced or removed. Typical warning labels, fitted within the platesetter, are shown in Figure 3.1 to Figure 3.15.

3.2.4 Mains Rating Labels

The serial number and model type appear on a mains rating label fitted to the rear panel. This is shown in Figure 3.3.

VOLUME 1 (3-6) S ERVICING S AFETY P RACTICE

C
92206

ETL LISTED CONFORMS TO UL STD 1950 US CERTIFIED TO CAN/USA STD C22.2 NO. 950

Product: Model No: Serial No: Volts

LUXEL V-9600CTP

230 15A

50/60Hz ~

Max Current: Manufactured:

This device complies with Part 15 of the FCC rules and is subject to the following two conditions: 1.This device may not cause any harmful interference. and 2.This device must accept any interference received including interference that may cause undesired operation. IMAGING ENGINE (REAR) This Class A digital apparatus meets all the requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numrique de la classe A respecte toutes les exigences du Rglement sur le matriel brouilleur du Canada. This laser conforms to the applicable requirements of 21 CFR Sub chapter J. FUJIFILM ELECTRONIC IMAGING LTD. PETERBOROUGH ENGLAND CLASS 1 LASER LASER KLASSE 1 LASER DE CLASSE 1 7550 854D 02

NOTE: MANUAL AND SEMI-AUTO PLATESETTERS ARE RATED AT 10 A MAX

Figure 3.3 Mains input - typical rating label

3.2.5 Drum and Traverse Warning Labels

Figure 3.4 illustrates the laser and spinner risks for the engineer when the drum end caps are removed and the interlocks are defeated.

L UXEL P LATESETTER VOLUME 1 (3-7)

Laser radiation when open AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

DANGER

WARNING
HIGH SPEED SPINNER ROTATION KEEP CLEAR

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

HIGH SPEED SPINNER ROTATION KEEP CLEAR NOTE: LABEL ON BOTH ENDS OF BAFFLE

WARNING

CAUTION
DO NOT STARE INTO BEAM
AVOID EXPOSURE Laser radiation Emitted from Aperture

LASER RADIATION

1250-45 BCamCP2 0.8mw 670nm

To EN60826-1, 21CFR Part 1040.10

VECTOR
TECHNOLOGY LIMITED

5794 0004

1002

WARNING MOVING PARTS

KEEP LOOSE CLOTHING, HAIR AND JEWELLERY ETC. CLEAR.

Figure 3.5 Drum user side - spinner and moving parts warning labels

3.2.6 Optics Base Warning Labels

Figure 3.6 shows the areas of risk for the engineer from exposed laser beams and high tension voltage when the optics base lid is removed.

L UXEL P LATESETTER VOLUME 1 (3-9)

DANGER
Laser radiation when open AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

LASER RADIATION - AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION WAVELENGTH & MAX OUTPUT 405 nm/45 W
CLASSIIIB LASER PRODUCT

Attention! high tension Vorsicht! Hochspannung Prcaution! haute tension Precaucin! alta tensin

Figure 3.6 Optics base - laser and high tension warning labels

3.2.7 RFI, Interlock and Filter Box Warning Labels

Figure 3.7 shows the area of risk from high-tension voltage after the RFI box lid is removed.

VOLUME 1 (3-10) S ERVICING S AFETY PRACTICE

RFI BOX

Attention! high tension Vorsicht! Hochspannung Prcaution! haute tension Precaucin! alta tensin

Figure 3.7 RFI box - high-tension warning label

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 3.8 Interlock box - high-tension warning labels

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

MAINS FILTER BOX

ENGINE (SERVICE SIDE)

Figure 3.9 Mains filter box - high-tension warning label

3.2.8 Drum Vacuum Pump Warning Label

Figure 3.10 shows the risk of hot running temperatures from the Busch drum vacuum pump.

Figure 3.10 Drum vacuum pump (Busch) - hot warning label

L UXEL P LATESETTER VOLUME 1 (3-13)

3.2.9 Interlocked Warning Labels (Automatic Only)

Figure 3.11 and Figure 3.13 show the areas of laser beam risk to the engineer when the interlocked covers are opened and the interlocks are defeated.
DANGER - Laser radiation when open and interlock defeated AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

DANGER - Laser radiation when open and interlock defeated AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

Figure 3.11 Interlock cover - interlocked warning label (Automatic)

VOLUME 1 (3-14) S ERVICING S AFETY PRACTICE

DANGER - Laser radiation when open and interlock defeated AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

SERVICE SIDE

USER SIDE

DANGER - Laser radiation when open and interlock defeated AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION

Figure 3.12 Interlock cover - interlocked warning label (semi-auto and manual)

3.2.10 Plate Transport Module Warning Labels

Figure 3.13 shows the areas of risk from moving parts on the PTM when the top cover is opened and the interlocks are defeated.

L UXEL P LATESETTER VOLUME 1 (3-15)

WARNING MOVING PARTS

KEEP LOOSE CLOTHING, HAIR AND JEWELLERY ETC. CLEAR.

Figure 3.13 PTM - moving parts warning label

3.2.11 Autofeeder Warning Labels

Figure 3.14 show the areas of risk from moving parts on the Autofeeder when all the covers are opened and the interlocks are overridden.

VOLUME 1 (3-16) S ERVICING S AFETY PRACTICE

WARNING MOVING PARTS

KEEP LOOSE CLOTHING, HAIR AND JEWELLERY ETC. CLEAR.

AUTOFEEDER (SERVICE SIDE)

WARNING ENSURE MAINS SUPPLY DISCONNECTED BEFORE SERVICING

Figure 3.14 Autofeeder - moving parts warning label

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)

Figure 3.15 Autofeeder - `Always Use Trolley' warning label

3.2.12 Safety Devices

Read all warning labels. Make sure that all safety controls, such as those listed below, are present and working correctly: Circuit breakers. Covers and doors. Guards. Panel indicators. Safety interlocks. Unless essential for commissioning or servicing, and under prescribed conditions, never override, negate, or bypass any of the above safety devices.

3.2.13 Unattended Equipment

Never leave equipment unattended unless in a safe condition with respect to the following hazards: Electrical. Mechanical. Laser Radiation.

VOLUME 1 (3-18) S ERVICING S AFETY PRACTICE

Chemical. Spinner. Pneumatics.

3.2.14 Dust Prevention

To avoid dust contamination of the machine, it is important to restrict to a minimum any operation with covers, lids or doors removed or open.

3.2.15 Electrical Safety

WARNING: Do not remove panels, lids or covers, unless instructed to do so by this or other related manuals. Hazardous mains voltages are present behind panels.

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 substances are present in the atmosphere. Avoid leaving electrical cables trailing where anyone may trip over them.

3.2.16 Mechanical Safety

WARNING: .Do not attempt to lift heavy equipment or assemblies by yourself.

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) B) C) D) E)

elevator chain pulley system spinner cassette and plate transport mechanisms plate push bar punch and centerer.

L UXEL P LATESETTER VOLUME 1 (3-19)

3.2.17 Chemical Safety

The guidelines below must be followed when storing or handling highly flammable liquids. Store bulk supplies in a metal cabinet marked with a `flammable liquid' label of an approved design. For use in the work area, decant the liquid to a container with a maximum capacity of 250 mL. The use of a safety dispenser is recommended. Do not use the liquid near to non-flameproofed electrical equipment. Do not use the liquid near to a naked flame. DO NOT SMOKE.

3.2.18 Spinner Safety

3.2.18.1 Moving Parts Safety
While the interlocks are over-ridden, a high-speed spinner mirror presents a danger for the service engineer.
NOTE: At idle speed, spinner rotation is a direct multiple of some interior lighting frequencies. This could make the spinner mirror appear as stationary. WARNING: The spinner rotates at very high speeds and can cause serious injury if accidentally touched. Make sure the spinner has stopped rotating before accessing a drum with the interlocks defeated.

Use the Main Diagnostics (diagnostics/service/spinner/stop) command to halt the spinner.

3.2.18.2 Acoustic Noise Safety

While the spinner is running and the covers on the Engine are removed, there is a sound level of up to 65 dBA.
WARNING: Always use appropriate ear protection devices before working on or around a rotating spinner.

3.3 Safety Interlocks (All Variants)

This section applies to all variants. See Volume 2 Figure 9.10 and Volume 2 Section 6.3.3 which describes the interlock system. The platesetter system includes two safety control facilities for protecting the operator and engineer from mechanical, laser and electrical hazards. These are: An interlocked cover system on the covers and doors used by the operator. See Volume 2 Section 6.4 describing the controls and wiring, and Section 3.3.1 showing the location of the covers. Note that the covers on the service side and Autofeeder are locked and must only opened by a FFEI-approved and trained engineer. An emergency stop system for the operator to rapidly switch off power to all motors, the laser and spinner. See Section 3.4.

VOLUME 1 (3-20) S ERVICING S AFETY PRACTICE

3.3.1 Interlocked Covers

Figure 3.16 shows a set of six protected covers that operate as interlocks to switch off power to the media handling motors, spinner and laser.

Figure 3.16 Interlocked covers (automatic)

The following covers are interlocked on an automatic platesetter (see Figure 3.16):
1. 2. 3. 4. 5. 6.

Buffer: top Engine: top output side Engine: user side Engine: service side Engine: top input side Plate Transport Module: top

The following covers are interlocked on a semi-automatic and manual platesetter (see Figure 3.17):
1. 2. 3. 4.

Engine: user side cover Engine: top input cover Engine: top output cover Engine: service side cover.

L UXEL P LATESETTER VOLUME 1 (3-21)

2 3

SERVICE SIDE (FOR SERVICE ENGINEER ONLY)

USER SIDE (FOR OPERATOR)

Figure 3.17 Interlocked covers (semi-auto and manual)

WARNING: If the platesetter has to be run with a cover open and the interlocks overridden, 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 procedure.

3.3.2 Locked Covers

All covers fitted on the service side of the Engine and PTM, and all covers on the Autofeeder are locked with screw fixings described in Volume 3 Section 1.3. After completing a service visit, make sure that the removed covers are securely locked again. This is to ensure that the operator can only access plates from the openings shown in the Operator and Safety Manuals.

VOLUME 1 (3-22) S ERVICING S AFETY PRACTICE

3.4 Emergency Stop Circuit

This section applies to Automatic and Manual variants. See also Volume 2 Section 6.3.3 which describes the emergency stop circuit. Emergency stop switches are accessible on the: PTM (Automatic) - see Figure 3.18. Engine (Manual) - see Figure 3.19. As soon as the stop switch is pressed, an emergency relay immediately removes all electrical supply to the laser, traverse and plate handling mechanisms. Emergency stops are fuse-protected and are only able to be overridden by an approved service engineer.

3.4.0.1 Emergency Stop Operation

WARNING: AC Mains supply is still live at the mains filter and 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 Engine.

PRESS DOWN TO STOP

AUTOFEEDER

PTM

Figure 3.18 Location of emergency stop switches (Fully-Automatic)

L UXEL P LATESETTER VOLUME 1 (3-23)

Figure 3.19 Location of emergency stop switch (Manual)

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 current 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

mains distribution box next to the platesetter.

4.

Supply is not restarted until the steps below are completed in the following order:
A)

The emergency stop button is reset by turning the red button in the indicated direction. This resumes the 24 VDC supply and re-energises the emergency stop contactor. The ON/OFF circuit breaker is switched on again.

B)

3.5 Mechanical Safety

This section details the main mechanical areas of risk for the service engineer when the covers are removed and the interlocks are defeated.

3.5.1 At the Autofeeder (Automatic Only)

WARNING: Autofeeder mechanisms potentially present a risk of injury from moving assemblies when the interlocks are defeated.

The Autofeeder is an elevator system with a mechanical set of chains and pulleys 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.

3.5.2 At the Plate Transport Module (Automatic Only)

A plate feed mechanism between the Autofeeder and the Engine pulls the cassette forward using two motor-driven arms.

3.5.3 Inside the Drum (All Variants)

A motor-driven push bar moves the plate from the input module to the punch.

3.6 Antistatic Precautions (All Variants)

This section applies to the Automatic, Semi-Automatic and Manual variants.
CAUTION: Do not handle exposed electronics. The components may be electrostatically damaged leading to equipment errors.

The Luxel CTP contains electronic components which are susceptible to static damage. When clearing jams, cleaning a device, or performing routine maintenance 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 protective wrapper. Do not place it on the wrapper, the outside of which could be electrostatically 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.

3.6.1 Field Service Antistatic Kit

See Figure 3.20. The following figure shows the recommended on-site service station using a field service antistatic kit.
CAUTION: Use the disposable antistatic wrist-strap. Failure to do so may result in damage to the board.

A disposable wrist strap is used to connect the engineer to an earthed (ground) point on the equipment (usually the chassis). To achieve this, the wrist strap is adhesive-backed. The equipment must be plugged into an earthed socket (but not switched on) to ensure a path to ground. The main antistatic recommendations are as follows: Always ensure a wrist-strap is connected to earth. Only personnel that are static-protected should touch boards or exposed internal components. Any board to be fitted should be kept within its antistatic enclosure until needed. If a board is removed, always pack it in an approved static-safe bag and seal the opening to provide a Faraday enclosure.
CONDUCTIVE MAT

CHASSIS

EARTH STRAP CLIPPED TO EXPOSED CHASSIS

POWER OFF MAINS PLUG EARTH

ANTISTATIC FIELD SERVICE KIT (9998-7920)

WRIST STRAP

Figure 3.20 Antistatic handling station

VOLUME 1 (3-26) S ERVICING S AFETY PRACTICE

Volume-Chapt er

2-1

PLATESETTER DIAGNOSTICS
This chapter describes how to use the test and utility commands in Main Diagnostics required for a service visit.

1.1 Introducing Luxel CTP Diagnostics

Features of the Luxel Violet diagnostic system are: Runs a set of POST checks on application start up. Runs as embedded firmware on the System Board with an RS232 link to a VT100 terminal or a PC HyperTerminal. Uses a set of Log Utilities, Test and Service menus, under Main> diagnostics prompt, that present selectable commands for field service diagnostics.

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

Introducing Luxel CTP Diagnostics .......................................................................... 1-1 Booting the Platesetter .............................................................................................. 1-2 Introducing Main Diagnostics ................................................................................... 1-6 Introducing Diagnostic Tests ....................................................................................1-6 Describing MMI Error Codes ................................................................................... 1-10 How to Use Main Diagnostics ................................................................................. 1-12 Running Main Diagnostics ......................................................................................1-19 Using Log Utils Menus .............................................................................................1-19 Using Test Menus ..................................................................................................... 1-27 Using Service Menus ............................................................................................... 1-30 Checking Config and NVRAM Data......................................................................... 1-60 Upgrading Embedded Firmware ............................................................................. 1-66 Setting Up Persistent Images ..................................................................................1-67 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.

VOLUME 2 (1-2) P LATESETTER D IAGNOSTICS

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 hierarchical 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 commissioning the system. See Section 1.5.

MMI Media Tools

A facility on the MMI that allows the operator or engineer to select/park a cassette 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 subsystem (optics, spinner, traverse, etc) reports an error. See Section 1.5.

1.2 Booting the Platesetter

Figure 1.1 shows the system software sequence for booting up and starting the machine application. See Section 1.5 for details on MMI errors codes and Section 1.4 which describes the tests in more detail.

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BOOT SYSTEM
POWER UP

CPU DIAGNOSTICS

FAIL

BOARD SHUTS DOWN

CHECK FLASH CODE

IF FLASH CODE CORRUPTS OR CONTROL+C PRESSED OR TOUCHSCREEN PRESSED

REMAIN IN BOOT MODE (READY TO DOWNLOAD F/W)

SETS UP HDD AND NVRAM

CONTROL + C FOR BY-PASS MODE

RUN DIAGNOSTICS

APPLICATION SYSTEM
RUN POST CHECKS (SYSTEM) DISPLAY ERROR START APPLICATION

READY TO SCAN

Figure 1.1 System Bootup sequence

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.

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1.2.1 Boot Sequence and Initialisation

The system boot sequence runs as follows:

Boot Sequence
1. 2.

When power is switched on, each CAN node PCB (System, VBOMB, STB and FHMB) resets its firmware application code. Start-up code provides the system with a minimum level of operating functionality for the application to run. Some of these start-up operations include:

3.

SYSTEM

4 4 4 4 4 4 4 4

Running initial board self tests. Starting the MMI. Check for the presence of a diagnostic terminal monitor. Initialise hardware without switching on the lasers or motors. Initialise the CAN bus.

Start-up code on the System PCB continues to: Establish CAN communications with all node boards. Build configuration records and log differences. Initialise the top level software modules.

OPTICS

TRAVERSE ELEVATOR (FHMB2)

DRUM I/P (FHMB1)

DRUM O/P (FHMB4) PLATE O/P (FHMB3)

PROCESSOR NOT READY

Figure 1.2 Boot screen - startup icons (fully-automatic)

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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: operation of ROM, RAM and processor interrupts

5. If no errors are found during the POST checks, each PCB confirms its status

Initialisation Sequence
6. Each node PCB initialises its subordinate modules independently of the Sys-

7. During the initialisation stage:

A)

Initialisation Homing Sequence

8. Initialisation also includes assembly homing and limit checks:
A) B) C) D) E) F)

9. If an error is found, an error symbol appears in the Error Handling screen

4 4 4 4 4
B) C) D) E)

communication to the node boards: System Board, FHMBs, STB and VBOMB. power supply line voltages integrity of NVRAM configuration files integrity of System Registry

to the System PCB and its Boot screen icon turns from grey to bold. If a PCB check fails, its screen icon remains greyed-out. See also Figure 1.2 and Step 9. below.

tem Board. Because all the hardware and mechanical dependencies vary with type of machine configuration, the order of module start-up is resolved locally.

The System Board builds a record of the machine's configuration (board IDs, serial numbers, etc) and checks whether this matches the previous configuration. Configuration data is held in NVRAM. If a platesetter cover is open (with the interlocks enabled), power to all the PCBs is lost except on the System Board, so only a partial initialisation is completed. A plate left in the machine is ejected if the trailing edge has passed BS50; otherwise it is reversed back into the cassette. A cassette left in the PTM is withdrawn into the Autofeeder. Plate processor is checked for connection and on/off status.

Push bar is moved down and up again to check motor operation. Traverse carriage creep is checked by moving the carriage to the user end. Spinner rotates at maximum speed. All the optics motors are checked for home datum positioning and travel limits. Traverse carriage moves back to start of scan position at the service end. laser calibration check commences when the traverse is aligned with the Fast Photo Detect sensor (FPD).

showing:

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10. Errors are either fatal or non-fatal:

1.3 Introducing Main Diagnostics

Main Diagnostics consists of a suite of tests and utilities that are run from a menu system shown in Figure 1.3 below:

DEVELOPMENT (R&D USE ONLY)

The following menus are available from Main Menu:

Development Menu
This menu is only available to R&D and service engineers. Use with caution.

Diagnostics Menu
This is password-protected for the service engineer and includes all the commands considered useful for field sites. It has three submenus: Log Utils: these are commands for editing/displaying files, and saving/ restoring files to the Hard disk (see Section 1.8).

4 4

the location of the module at fault (optics base, spinner, etc) an error code.

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

START (R&D USE ONLY)

STAND ALONE (R&D USE ONLY)

DIAGNOSTICS

LOG

LOG UTILS MENU

TEST MENU

SERVICE MENU

Figure 1.3 Main Diagnostics - menu map

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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.

1.4 Introducing Diagnostic Tests

The platesetter performs a set of System self-tests when the Run Diagnostics button on the MMI TOOLS menu or Error Handling menu is pressed. These extended tests include all of the boot-up tests. The SIO online Luxel V/Vx-Series Error Codes Guide describes all the MMI error codes in detail, including the System tests (codes 1000 to 1999)

1.4.1 System Self-Test Error Codes

System tests are run in the following sequence producing the following error codes:
1. Check processor core: ROM, RAM, Interrupts, NVRAM storage and slave

boards to give Error Codes. ROM: 1001 RAM: 1002 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

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

4 4 4 4 4

Code: 1028

checked to give Error Codes: LPD motor: 1009 ND motor: 1010

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9.

10. Spinner runs up to speed and is able to maintain lock. Error Code: 1018. 11. Optical recalibration check on all optical sensors.

1.4.2 System Self-Test Descriptions

This section describes the following system self-tests that run from the MMI and from Main Diagnostics:

1.4.2.1 ROM Test

This addresses Flash memory and checks data over the data bus. A CRC is performed in two areas of Flash: the boot system and the application system.

1.4.2.2 RAM Test

This checks RAM and data over the data bus. If an error is found a fatal error is flagged.

1.4.2.3 Interrupt Tests

This checks that the interrupt lines to the processor are not held active. If an error is found a fatal error is flagged.

1.4.2.4 Registry Check

This checks if the system configuration has been modified.

1.4.2.5 PSU Voltage Supply Check

The FHMB checks that the +24, +5 and +15 VDC lines are within tolerance.

1.4.2.6 NVRAM Integrity Test

This checks that the configuration files contain data that is specific to the system. The data is compared to a checksum. If the data is corrupt, the data is restored to its default. The engineer can load backup data from the hard disk if default data is not possible.

1.4.2.7 Stepper Motor Tests Datum Tests

This checks that the optics motors Home correctly by driving each motor to its datum position: Focus motor Laser power detector motor Aperture control motor ND filter motor.

4 4 4

Beam converter motor: 1011 Focus motor: 1012 Focus sensor: 1013.

All DC motor assemblies. Error Code: 1007.

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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.

Full Travel Tests

This checks that the optics motors can be stepped freely over the length of the drive rail by driving each motor to its end stop and returning to zero position. The zero position is compared to the datum sensor to check that no steps are missing.

Plate Handling Motors

The plate handling motors for the FHMBs are checked as part of the system selftests.

1.4.2.8 DC Motor Assembly Tests

This checks that the plate handling DC motors move to an initial position, one other position and return again: A fatal error is flagged if no output is detected from the limit sensor after a set period of time. The check cannot determine if the sensor or the motor is at fault.

1.4.2.9 Spinner Checks

This checks that the spinner can run at full and idle speed. It is run at each speed for 30 seconds to check that phase lock is maintained.

1.4.2.10 Optics Checks

The optics stepper motors are checked for home datum position and travel limits. A beam coincidence check is described in Section 1.10.4.1.

1.4.2.11 Output Data Path Checks

This checks the digital data path from the HDD to the serialiser. The serialiser CRC circuit is initialised. A test image is loaded from the disk and the CRC value of its data is read at a point just before the optics base and compared with its known value.

1.4.2.12 Processor Comms Checks

If the Processor operates with the same protocol interface as the platesetter, the check ensures there is a communication connection. A loopback test to verify data output requires a loopback connector to be fitted.

1.4.3 MMI Test Images

When the Run Test Image option is selected from the MMI Maintenance menu, a set of persistent images (PI) on the Engine hard disk drive (HDD) can be chosen as a test output. When selected, the platesetter automatically exposes the image and ejects it. Standard PIs are: Grid for Registration checks Tint at 50 % 4 x S&T CMYK.

VOLUME 2 (1-10) P LATESETTER D IAGNOSTICS

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.

1.5 Describing MMI Error Codes

1.5.1 Types of Errors
See the SIO online Luxel V/Vx-Series Error Codes Guide for a list of code descriptions and recovery steps for the service engineer. Errors and their recovery procedures for the user are explained in the Luxel Platesetter Operator's Manual. Error codes appear on an MMI Error Handling screen whenever a machine or a plate transport failure is detected. Errors are one of two types: FATAL: these faults prevent the platesetter from operating. When a fatal error occurs, the operator should follow a recommended recovery procedure. Failure of the machine to recover automatically will cause the same Error Handling screen to reappear. NON-FATAL: these are temporary faults that should not prevent the machine from operating but may have caused the current image to fail. The system will continue to scan other images on the queue. Non-fatal errors are also cause by system alerts calling for maintenance attention. Fatal and non-fatal error codes are arranged into the following groups:
1. 2. 3. 4. 5. 6. 7. 8. 9.

Optics: 100 - 199. Optical module and alignment errors. Traverse: 200 - 299. Traverse errors. Spinner: 300 - 399. Spinner errors. (Note that error group 400 to 499 is reserved). Environment: 500 - 599. Temperature, chad tray and cover errors. Input Data Controller: 600 - 699. IDC errors on image data from the RIP server to the HDD. Output Data Path: 700 - 799. OPD errors on image data from the HDD to the optics base module. (Note that error group 800 to 899 is reserved). Media Processor: 900 - 999. Processor and comms link errors to the Engine. Diagnostic Self Tests: 1000 - 1999. Diagnostic error reports run from the MMI. Media Transport: 1200 - 1299. General media transport control errors.

10. Elevator: 1300 - 1399. Elevator errors. 11. Plate Feed (PTM): 1500 - 1599. Module and media jam errors on the PTM. 12. Input Module: 1600 - 1699. Module and media jam errors on the input mod-

ule.

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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.

1.5.2 Fatal Error Closedown Sequence

Detected FATAL errors force the system into a controlled state that allows the machine to recover automatically and provide adequate information for the operator or service engineer to fault-find. As soon as a FATAL error occurs, the system starts an automatic set of controlled closedown operations that leave the machine in a state where remaining plates are not at risk of accidental `fogging'. After a closedown has finished, the machine is in a safe state for the operator to access the problem area. Closedown operations are described fully in the Luxel V/Vx-Series Error Codes Engineer's Guide available on SIO.

1.5.3 Error Logging

If a fatal error occurs it is automatically logged on the HDD as an error log (Elog) file called elogNew.txt. Note that the name is case-sensitive. Alternatively, an Elog file can be generated (and saved to disk) at any prompt in the diagnostic/service menu by entering:
elog [Return]

You can view and capture an Elog file for further analysis by:
1. List all the files on the HDD by entering:
dfs> ls

2. Scroll down to find the elogNew.txt file. 3. Enter the R&D menu from the main> prompt (password boxer.dev). 4. Enter the following:
streams [Return]

5. Enable Hyperterminal text capture from the Transfer menu and type more off

to avoid the need to keep pressing the spacebar.

read general/elogNew.txt

6. To display the file, enter:

1.5.4 Using the SaveLog Utility

The current set of NVRAM parameters and logged statistics for assessing machine history can be transferred as a file from the Engine HDD to a floppy disk on the RIP PC.

1. Make a note of the pathname to the RIP PC floppy drive. 2. Run this facility from the Windows Start menu as (or equivalent):

VOLUME 2 (1-12) P LATESETTER D IAGNOSTICS

Program / FUJIFILM Electronic Imaging Ltd / Recorder Utilities / SaveLog

to open a window from where you can select the required data from the menu:
0 2 4 Error/Status NVRAM Test SCSI Log

99 All

3. Insert a floppy disk and save the selected data by entering a menu number and
the pathname.

1.6 How to Use Main Diagnostics

Main Diagnostics is designed to provide a set of tests (go/no go) and useful utilities for rapid confirmation of the system's operation. If you encounter any problems while running Main Diagnostics, call FFEI Customer Support (UK).

1.6.1 Setting up a Terminal Window

Main Diagnostics are run from any terminal (PC, laptop, RIP server, etc) that is able to present a HyperTerminal or VT100 type emulation window. These utilities and tests are embedded on the System PCB allowing the service engineer to enter diagnostic commands and read return data from the main modules. Before commencing Main Diagnostics, check that: an RS232 connection from the terminal to the RFI box (DIAGS port) is fitted. the platesetter is switched on. Use the following method to set up the communications link between the platesetter and a HyperTerminal on the RIP server.
1. 2.

Open a terminal window from the desktop Start button: Set the Properties options for the platesetter comms link to the terminal as follows:

Connect: COM1 or 2 Settings: Autodetect 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.

Programs

FUJIFILM

RecorderUtilities

Diagnostic Terminal

4 4 4

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1.6.2 Accessing Diagnostics

1.6.2.1 Main Menus
To enter Main Diagnostics carry out the following:
1. Power up the platesetter from the Engine on/off switch. 2. Open a terminal window, for instance, HyperTerminal on a PC. 3. Once the application has loaded, the main> prompt appears (press [Return] if

it is not displayed). Enter the following global command to view the diagnostic options as a formatted screen of menus (if required):
main> mode 1

Or enter the mode as 0 to obtain full screen text. Pressing [Tab] [Tab] displays the current options available.

1.6.2.2 Obtaining the Diagnostics Menu

Diagnostic tests and utilities for the service engineer are available by entering:
main>diagnostics Enter password: **** (example 'uk1') TIME ... DATE .... Date & Time Correct? (y/n) : y diagnostics>

Valid passwords are issued from FFEI Customer Support (UK).

1.6.3 Entering Diagnostic Commands

There are two types of command: those which directly select tests or utilities those which select another group (or sub-menu) of commands and have the suffix
/.. When a command is entered, the screen displays all the available command options.

To navigate between menus, enter the command name and press Return to move down a menu level, or .. Return to move up a menu level. After entering the first two or three letters of a command from any prompt and pressing the [Tab] key, the remainder of the command name is displayed. Where a boxed list shows `More ->', press the [Tab] [Tab] to display the additional commands. The screen needs to be in unboxed mode before the commands are listed. Other commands require extra parameters to be entered in the form of numbers or letters. If a command is not entered without the required parameter(s), a `USAGE' message appears showing a list of valid parameters for the command. Commands can be invoked using its pathname; for instance, Diagnostics> service/
optics/laser.

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1.6.4 Using Global Commands

Global commands do not appear in the menu structure and are displayed with the Help command. They can be entered regardless of the current menu position. All the global commands, along with the menu items available for the current menu level, are displayed as a list by typing
help [Return] or [?] [Return]

To select a command, type its name, followed by:

[Return] or [Enter]

The global commands and their functions are shown in Table 1.1. Note the following: All diagnostics commands are case independent. For example, HELP, help or HeLp, all select the same command. Diagnostics commands can be abbreviated. For example, to select the Help command you can enter h, he, hel or help. You can enter the first few letters of a command and press [Tab] to finish the entry. If several commands begin with the same letters, then sufficient letters must be typed to make the selection unique. For example, if there are two commands, help and hello and he is entered, the system responds with a command entry error. Some commands can be modified by adding subsidiary commands. For example, enter:
soak soe

and the soak command is modified so that it Stops On an Error. Certain commands require responses to questions.
Table 1.1 Global commands
Global Command break ddeb edbg <num> ddbg <num> repeat showscript <name> runscript <name> star Description A forced breakpoint for debugging Display debug files enables debug Disables a specific debug Executes the command string count times Displays the contents of a specified script Runs name script Enables/disables the rotating star activity indicator Deletes named script Erases all script files Records the command lines into a script file

deletescript <name> zeroscripts record <name>

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Table 1.1 Global commands (Continued)

verbose run <name> help Selects the level of messages for display Run executable file Lists all menu items currently available and displays details about tests Lists all menu items currently available and displays details about tests Soak a test or a submenu of tests Displays machine status problems Enables individual tests or submenus for soak testing Disables individual tests or submenus for soak testing Locates a command within the menu structure Displays the current menu path Enter Monitor mode (boxed/unboxed) Deletes a script Enters the evt menu Returns cursor to parent menu Returns cursor to parent menu Erases all scripts Hard reset Soft reset

soak <test> <num> sys_status enable <command name>

disable <command name>

find <command name> path mode <1/0> deletscript <name> evt/ ../ quit/ zeroscripts hreset sreset

1.6.5 Using Verbose

The verbose command controls the messages appearing on the Log file during soak tests. On its own, this command reports the status of the Verbose function (on or off). Use verbose on and verbose off to switch the function on and off respectively. When Verbose is on, all messages are displayed and messages beginning with: **, --, ++ and ^^ are logged to RAM (if RAM logging is enabled).
NOTE: Only error messages (indicated with**) are logged to Flash memory.

When Verbose is off, only error messages are displayed and logged to application, RAM or Flash.
NOTE: For troubleshooting, always select the Verbose ON option.

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1.6.6 Running Soak Tests

The soak command runs all tests that are soak enabled in all sub-menus below the current level. Tests and sub-menus that are soakable are indicated by an S suffix to the command name. If the S is in bold, the test is enabled. If the S is not bold, the test is not enabled. To soak all soakable tests and sub-menus, use the soak command. By selecting the diagnostics will run each soakable test once and will stop when an error occurs.
soak soe

To soak more than once, use: soak x where x is the required number of repetitions. To soak an individual test or sub-menu, enter soak x name, where x is the name of the test or sub-menu and name is the number of repeats. To select the stop-on-error code use the suffix soe. For example, soak 10 soe initiates a soak on all enabled tests 10 times and the tests will stop on any error
** An error stopped the soak test! [test name] To stop a soak test press [Ctrl-c].

If a soak test fails and the stop-on-error (SOE) flag has been set, then a message is displayed on the monitor: where [test name] is the name of the test which failed. To select the loop-on-error code use the suffix loe. For example soak 10 loe initiates a soak on all enabled tests 10 times and the tests will loop indefinitely on any error. The enable command enables soak tests. Individual tests can be enabled. For example enable test3 enables command Test3 for soak testing. If enable all is entered then every command in all sub-menus will be enabled. The disable command disables soak tests. Individual tests can be disabled. For example disable test3 disables command Test3 for soak testing. If disable all is entered then every command in all submenus will be disabled. Test results can be logged to application, RAM, or Flash memory for subsequent examination.
time_stamp.

Time information can be optionally added to the error log using the command Temperature information may be also added to the error log using the command temp_stamp.

1.6.6.1 Using the Debug Utility

The Debug utility allow you to switch diagnostic information on/off for each of the machine software tasks and display the sequence of events as they occur on the system.

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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.
Table 1.2 Debug task numbers
Number 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Debug Check Event logging Std processing Std exits Event timers CAN driver Input data controller Output data controller Local disk debug switch EOD info MMI GUI Exposer Spinner running to idle speed APC SCSI NVRAM Media management Not used Traverse EOD circling Number 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Debug Check Calibration info Test pattern generator Spinner contamination Laser System Board temp sense handling Delay detector EODD port control Media transport Not used Not used Characterisation using LPD Expose calibration Calibration files O/P event log text to terminal Not used Enable dump of function calls elog LSB control register dump SCSI - specific setter detail Laser environment details

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Table 1.2 Debug task numbers (Continued)

19 20 Beam coincidence Media processor 40 41 42 Laser Aging details Not used Laser Dew Point detail

1.6.6.2 Using Script Commands

A script allows you to create a sequence of Main commands and parameters and run them as an executable file. This facility means that you can generate useful repetitive routines without having to constantly re-enter command lines. All scripts are held in a separate script file.

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, showscript 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.

1.6.6.3 Obtaining Command Line Help

If you are working from a service menu, use the global Help command to obtain

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further text details on each command in the menu. To obtain details on parameters for a command, enter the command name and press [Return]. This gives a usage line showing each parameter; for instance if you enter:
diagnostics/service/cassette_dbases> addm

the required parameters are displayed on the following line:

Usage: addm <name> <width> <height> <init quant> <thickness> <type>

Alternatively, you can obtain full usage details of the command by entering ? before the command name, for example:
diagnostics/service/optics/move_motors> ? beam_re_pos

1.7 Running Main Diagnostics

Main Diagnostics are divided into the three submenu options shown in Figure 1.4.:
1. Log Utils: allows you to check and modify parameters for NVRAM, registry

values, machine statistics and errors, and copy the configuration files to the Engine HDD. motors are operating correctly. Some of these tests are also run as POST checks during system initialisation.

2. Test: allows you to run a set of test commands to check, for instance, if the

3. Service: provides a set of useful software utilities for checking equipment.

For instance, moving actuators (motors and solenoids), displaying the current state of actuators and sensors, etc

Figure 1.4 Diagnostics menu

1.8 Using Log Utils Menus

.

Log_utils menu provides a set of commands forr displaying the machine statistics, accessing and updating the Registry/Configuration files and accessing the

VOLUME 2 (1-20) P LATESETTER D IAGNOSTICS

NVRAM parameters.

1.8.1 log_utils menu

disp_stats
Displays machine statistics as shown in Figure 1.5: Parameters: [raw] to obtain a plain ascii file.
Cassette selects 295 Cassette failures 1 Shelf selects 391 Elevator failures 0 Plates Loaded 1786 Plates Retracted 11 Paper Sheets Handled 1755 Exposes 2426 Fast Spinner Time 180390 Spinner Failures 0 Media Used(width < 520mm) 126 Media Used(width < 750mm) 341 Media Used(width < 1050mm) 1150 Media Used(width >= 1050mm) 153 Punches 989 Media Jams (Feeder) 2 Media Jams (Paper Bin) 0 Media Jams (Drum) 4 Media Jams (O/P Buff) 9 Paper Past Diverter 0 Feeder Faults 3 Drum Vacuum Secs 165562 Auto-Feeder Pump Secs 107592 Punches since chad 120 Compression(1-1.5) 3 Compression(1.5-2) 17 Compression(2-2.5) 51 Compression(2.5-3.5) 11 Compression(3.5-5) 82 Compression(5+) 3143 Lowest Comp x 100 87 Highest Comp x 100 9811 Image(500mmx500mm) 1138 Image(500mmx750mm) 1223 Image(500mmx1000mm) 533 Image(500mmx1162mm) 0 Image(960mmx500mm) 2737 Image(960mmx750mm) 490 Image(960mmx1000mm) 1213 Image(960mmx1162mm) 1346122834 Total Op Time Secs 13484016 Total Scan Time Secs 308433 ND_FULL_POWER_POD 167 BEAM_CO_X_POSN_FULL_POWER 123 BEAM_CO_Y_POSN_FULL_POWER -129 EODD_LB_X_OFFSET_FULL_POWER 1984 EODD_LB_Y_OFFSET_FULL_POWER 2256 Laser On Time Secs 0

Figure 1.5 disp_stats screen

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 subsequent 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 command or when the application runs the diagnostic every 24 hours. Use this data to predict when the laser will fail by determining when the operating 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 Date Oct 28 16:04:17 2002 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Laser current. 1174 0 0 0 0 0

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].

1.8.2 log_utils/configuration menu

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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) B) C) D) E) F) G)

<ssb_config> <REGISTRY_SSB_ID> <stb_config> <REGISTRY_STB_ID> <vbomb_config> <REGISTRY_VBOMB_ID> <fhmb1_config> <REGISTRY_FHMB1_ID> <fhmb2_config> <REGISTRY_FHMB2_ID> <fhmb3_config> <REGISTRY_FHMB3_ID> <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.

1.8.3 log utils/nvram menu

Use this menu to view NVRAM parameters and edit values used for the: laser module

VOLUME 2 (1-24) P LATESETTER D IAGNOSTICS

read and write the traverse centre position read and write the image offset value on the plate enter a new cage creep utility number of traverses and the interval in hours between the fast laser contamination checks.

LCPD_params
This command stores the original parameters for the laser when it was first manufactured. The modified working values are stored in NVRAM after laser aging, power balance and extinction ratio are setup. It allows you to display/edit the NVRAM laser parameters for a replaced laser module. Enter lcpd_params to display the current parameter values for the laser module. Alternatively, enter lcpd_params change to display the parameters for editing before they are automatically saved to NVRAM. Revise the parameters as follows (from top to bottom): Enter new decimal values supplied with the laser module data sheet, see Volume 3 Section 4.3.3. Laser drive power Laser bias current Laser current limit Laser wavelength. The laser drive power is always 1000 and the other values are specified on the laser module label.

ORIGINAL DRIVE DAC X VALUE (DEC) ORIGINAL BIAS DAC X VAL (DEC) ORIGINAL CURRENT LIMIT DAC X VAL (DEC) ORIGINAL DRIVE DAC Y VALUE (DEC) ORIGINAL BIAS DAC Y VAL (DEC) ORIGINAL CURRENT LIMIT DAC Y VAL (DEC) LASER X WAVELENGTH (DEC) LASER Y WAVELENGTH (DEC)

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)

Parameters: [0 (not fitted) | 1 (fitted)].

dew_protection
This should be set to 1 if the dew protection Temperature and Humidity Sensor PCB is fitted, otherwise it is set to 0. Parameters: [0 (not protected) | 1 (protected)].

exposure_calibration
Set this to 1 to enable a fixed energy level on the plate using the MMI exposure calibration facility. Parameters: [0 (disabled) | 1 (enabled)].

spinner_contamination
Controls the operation of the spinner contamination check. Parameters: [ 0 (disabled) | 1 (enabled)].

temperature_compensation
R&D use only. Do not use. Parameters: [0 (not compensated) | 1 (compensated)].

reset_spin_clean_level
A new spinner contamination clean level is set up the next time exposure calibration is executed. Do not run this command unless the spinner is changed. Parameters: [None].

rd_centre_posn
Reads the traverse centre position (in microns) from NVRAM, see also Volume 3 Section 1.8.2.5. Parameters: [None].

wr_centre_posn
Writes the traverse centre position (in microns) to NVRAM, see also Volume 3 Section 1.8.2.5. Parameters: [value = microns].

rd_edge_sensor_offset
Reads the NVRAM edge detect sensor offset in microns. Parameters: [None].

wr_edge_sensor_offset
Writes the NVRAM edge detect sensor offset in microns. Parameters: [microns]

rd_image_offset
Displays the current image base offset value from the centre of the punch hole, see also Volume 3 Section 1.8.2.6. Parameters: [None].

VOLUME 2 (1-26) P LATESETTER D IAGNOSTICS

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].

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1.9 Using Test Menus

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.

1.9.1 test/basic menu

psu
The PSU_TEST is executed and the result shown as `PASSED' or `FAILED'. Parameters: [None].

nvram
Checks for NVRAM integrity. Parameters: [None].

clock
Tests for the correct date and clock output for the set time zone. Parameters: [None].

1.9.2 test/registry menu

reg_powerup
Use this utility to check if the hard/soft/firmware revisions made on the system are compatible with the existing configuration. This command also runs as part of the POST checks on startup. Parameters: [HDD | system].

VOLUME 2 (1-28) P LATESETTER D IAGNOSTICS

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 modification, 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 production 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 displayed. Now check that the revised details are valid by running the Reg_power test:
registry> reg_powerup

1.9.3 test/optics_motors menu

all_home
Checks that each optics stepper motor (focus, low power detector, beam converter and ND filter) reach their datum position, see Section 1.4.2. Parameters: [None].

LPD_motor
Checks the LPD motor. Parameters: [None].

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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].

1.9.4 test/traverse menu

datum
Moves the carriage to the traverse datum position at the user end. Parameters: [None].

trav_test
To confirm the level of the platesetter, run trav_test which moves the carriage along the service end of the traverse for the number of traverses set by the cage_creep command. The default number is 10 which allows you to check if creep has exceeded the specification of 1 mm. To check the user end, enter the command as trav_test r. See Volume 3 Section 1.7.2 for the levelling procedure. This test takes several minutes to execute. Parameters: [r (starts at right - user end)].

1.9.5 test/spinner menu

spin_test
Runs the spinner tests, see Section 1.4.2. Parameters: [None]

contamination
Runs the spinner contamination check to indicate the percentage of degradation from a reference level. A large decline (30% or greater) would also be seen as a reduction in expose quality on the plate. The check requires a correctly set up FPD, see Volume 3 Section 4.3.9.2. Run reset_cont_lvl before running contamination. 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].

1.9.6 test/optics menu

beam_coincidence
Runs the BEAM_COINCIDENCE_TEST to set beam deflection alignment. Any failures, where beam_co is unable to align the beams, results in an optical error code. The test will automatically run a macro to: enable the debug command, edbg 19 switch on the laser. If there is a problem in running beam_co, then run the above macro commands separately and re-run beam_co. Parameters: [None]

deflector_check
Runs a set of tests to check X and Y beam alignments, deflector gains, beam crossing and angles on the POD. Outputs the results as PASS/FAIL:

Parameters: [None]

1.9.7 test/processor menu

status
Runs the PROCESSOR_COMMS_TEST to check the Engine communication link with the Processor. Parameters: [None]

1.10 Using Service Menus

Commands useful for running service utilities are available from the menu

4 4

Deflectors crossed (X and Y cables crossed) X and Y deflector x/y positions on the POD at midrange.

L UXEL P LATESETTER VOLUME 2 (1-31)

shown in Figure .

1.10.1 service/memory menu

NOTE: These commands are only used when directed by FFEI CustomerServices Ltd.

dmem
Displays the contents of System Board logical memory addresses for the application 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 ? command 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.

1.10.2 service/evt menu

The software process system runs about fifty multiple system tasks called STDs (State Transition Diagrams) which co-operate with each other by passing messages (or Events) along channels. EVT commands are normally used by R&D to display and manage these communications as a method of determine the cause of failure if the machine `hangs up'.
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 messages are numerous and will only make sense to R&D. Capture the full display

VOLUME 2 (1-32) P LATESETTER D IAGNOSTICS

of text output and consult FFEI Customer Support (UK). Parameters: [None].

sequence
This shows how the system reached its current state as a sequence of events. Use the following command: sequence -1 1000 to get the last 1000 state changes. Save the full display to a floppy disk as a text file and email the results to FFEI Customer Support (UK). Parameters: [std number | number of entries].

1.10.3 service/remote menu

tip
R&D use only.

rcmd
Executes a single command on a remote node. Parameters: [remote system ID | command to execute].

rlogin
This allows you to login and display data directly from an intelligent slave board without routing via the System Board. Use Help to check the list of commands available on each board. When starting rlogin, make a note of the messages to obtain information for exiting from the board main> prompt. Parameters: [ssb | stb | vbomb | fhmb1, etc]; enter [Ctrl-e] to close the session.

1.10.4 service/optics menu

Opening the optics submenu reveals the options shown above.

1.10.4.1 service/optics/laser menu

simlaser
R&D use only.

appl_status
R&D use only.

power_balance
Runs power balance at 48, 72 and 96 resolutions.

L UXEL P LATESETTER VOLUME 2 (1-33)

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 lenable 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:

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].

4 4

to increase the extinction ratio of a laser you need to decrease the bias current to decrease the extinction ratio of a laser you need to increase the bias current.

VOLUME 2 (1-34) P LATESETTER D IAGNOSTICS

Changing values Working Laser X bias dac value (dec) 563 Working Laser Y bias dac value (dec) 526 Remember Incorrect Values can cause damage dec Working Laser X bias dac value (dec) 563 Working Laser Y bias dac value (dec) 526 Confirm Change Updating Values UPDATE hex 233 20e

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 installation. 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 Original x current = 1212 read x current = 1260 end of life percentage = 50 End of life current 1818 Original y current = 1157 read y current = 1174 end of life percentage = 50 End of life current 1735 max rate of change = 7 about to do the x actual_rate calc. last x current = 1259 read x current = 1260 actual +ve rate of change 0 about to do the y actual_rate calc. last y current = 1175 read y current = 1174 actual +ve rate of change 0 previous x current limit = 415 new_current_limit x = 415 previous y current limit = 387 new_current_limit y = 387 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 Laser X extinction ratio = 205.442322 Laser Y extinction ratio = 193.664627

1.10.4.2 service/optics/motors menu

The Motor menu is divided into move_motors and simulate.

VOLUME 2 (1-36) P LATESETTER D IAGNOSTICS

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].

1.10.4.3 service/optics/optics_mmi setup screensM

Use this command to open a setup screen for automatically generating and exposing test strips from a set of editable default values. Each strip differs from the previous one by a `step value', enabling the operator to determine the optimum step position and store its 'final value' into NVRAM. Volume 3 Section 4.4 describes how to use this facility in more detail.

1.10.5 service/motors menu (stepper)

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. Parameters: [motorname]. See Table 1.3 for a list of motor names.

getmotor
Displays the currently selected motor name. Parameters: [None].

move
Use this command to move the currently selected motor a number of steps at a specified speed. Parameters: [distance of the move (in steps) | f = forwards; b = backwards | speed (steps per sec)]; for instance, move 80 f 400.

stop
Use this command to stop the currently selected motor. Parameters: [e = motor stopped with a holding current applied | d = motor stopped without a holding current applied].

movemore
Moves the currently selected motor a further number of steps after the move command has been invoked. Parameters: [steps]; enter, for example, as
movemore 20.

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].
Table 1.3 Stepper motor names
Setmotor Name focus beam_converter nd slow_speed stack_height push_bar centerer bridge_feed output_mtr p_pusher Description of Motor

Focus Beam Converter ND Wedge LPD stack height push bar centerer buffer BM38 on output module platen pusher

wait
Wait for the currently selected motor to stop. Parameters: [None].

1.10.6 service/sensors menu

Sensors can have long names (for instance, punch_motor_off_position) or short names (for instance bs2).

read_sensor
Use to read the on/off condition of an individual sensor, for example,
read_sensor bs9.

Parameters: [Sensor name].

eslog
Enables sensor timelines for event logging (elog). This allows you to check the status of a sensor during a sequence of machine events. Parameters: [None]

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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 sensor, 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].

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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 optoslot 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

Figure 1.6 Read_con (input sensors) screen (fully-automatic)

Figure 1.7 Read_con (output sensors) screen (fully-automatic)

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.

Figure 1.8 Read_con submenus

1.10.7 service/time menu

set_time
Allows you to set the real-time clock on the machine. Parameters: [YY | MM | DD | hh | mm | ss].

now
Displays the current time. Parameters: [None].

sleep
Use to add a machine pause in milliseconds, for example, sleep 100. Parameters: [mS].

gtime
Gets the VRTX time in (ticks). Parameters: [None].

1.10.8 service/traverse menu

init
Initialises the traverse servo motor.

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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 command 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 approximate 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 monitor. 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)].

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1.10.9 service/spinner menu

reset
Initialises the spinner control circuitry. Parameters: [None].

start
Starts the spinner and runs it up to full speed. Parameters: [speed (33 or 40)].

idle
Runs the spinner at idle speed. Parameters: [None].

stop
Stops the spinner - braking takes approximately 20 seconds (max). Parameters: [None].

index
R&D use only.

rd_image_offset
Displays the current image base offset value from the centre of the punch hole. Parameters: [None].

wr_image_offset
Writes a new image base offset position to NVRAM. Parameters: [new value (mm)].

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].

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Figure 1.9 Actuator names displayed (fully-automatic)

1.10.11 service/disk menu

If there are two Hard disk drives, they are selected as SCSI unit numbers 0 and 1. Unit 0 matches CHAN 1 drive; Unit 1 matches CHAN 2.

unit-no
Returns the SCSI number of the drive unit as (odd = 1; even = 0) if a parameter is not entered. Parameters: [0 | 1] to set the default unit for operating the commands below; for instance, unit-no 1.

scsi-id
Displays the device SCSI ID and default unit number. Parameters: [SCSI ID No] for instance, scsi_id 0.

test-unit-rdy
Returns the state of the default unit(s) and checks whether the unit is ready to run. Enter as test-unit-rdy after setting the unit number (unit-no). The test report indicates unit ready (++), unit, unit number and SCSI ID. Parameters: [None]

capacity
Indicates the status and size (in bytes) of the disk drive memory blocks of a default unit without a parameter. Also displays the blocks of logical addresses and block banks in byte decimals for free and used memory. Parameters: [SCSI ID no] for instance, capacity 0.

inquiry
Without a parameter, displays all the drive details (SCSI ID, vendor ID, product ID, etc) and completes checks on the default drive status. Parameters: [SCSI ID no] for instance, inquiry 0.

start-stop
Parameters: [1 (stop) | 0 (start)] to start and stop the default disk rotating. Enter a

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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.

1.10.11.1 service/disk/dfs menu

Opening the disk/dfs menu reveals the options shown above.

mountall
Mounts a new file system. If the system is already mounted, it is unmounted first. Make sure the dfs is initialised as part of the startup. Parameters: [None].

un-mountall
Unmounts the file system. Parameters: [None].

format-low
Scans the disk drive and checks all sectors for damage. Note that the complete check takes about 55 minutes. Parameters: [SCSI ID No].

sys-format
This reformats (i.e. repartitions) the drive and removes all unwanted files and images. Make sure that the Media/Cassette databases, NVRAM, PIs and Configuration data are regenerated on the new disk space. Record the existing database details on paper from dbase/dump and restore from on the MMI; use the Configuration options to save/restore NVRAM data; use the Registry options to display/update config data. Parameters: [None].

ls
List files in the current HDD directory; for instance, ls /general/* to list all files in the general folder. Parameters: [filename] or without a parameter lists all files.

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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].

1.10.12 service/testpatns menu

NOTE: Testpatns commands are entered using hyphens (-) and not underscores(_).

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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 output 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].

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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.

1.10.13 service/job_mgr menu

This facility allows you to create, delete or display the status of a media job on the Hard disk. As an alternative method, the service engineer can create jobs from the RIP and delete jobs from the Manage Job Queue option on the MMI Maintenance menu. There are two types of jobs: Expose and Media. Expose jobs are linked to transient or persistent images (PI). Transient (i.e. RIP) images are deleted once scanned; PI images remain on disk until explicitly deleted.
NOTE: To exit from job_manager, enter quit.

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 starting. Parameters: [None].

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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 function 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.

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dumpjob
Dumps the job description if it has not been processed. Parameter: [job ID].

1.10.13.1 service/image_mgr menu

init
Initialises the Job Manager and Image Manager. Parameters: [None].

rm
Deletes an image. Parameters: [job ID].

dumpimage
Displays the image descriptor settings. Parameters: [image name].

dir
Lists all the images (persistent and RIP transient) held on Engine HDD. Parameters: [None].

editjob
Opens a screen from where you can edit the default job parameters for a persistent image. Parameters: [image name]. This facility allows you to select an expose image and edit parameters. For instance, a set of commissioning pages (persistent images), installed on the platesetter Hard disk for scanning as test jobs where local parameters may need to be adjusted. These images are exposed directly from the MMI and not the RIP. A standard set of reference PIs are preloaded on the HDD to include: grid S&T page (CMYB). tint - 50% for tint prediction

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A spare set of PIs are also available on the Boxer CD.

1. Enter the utility, and:
image_mgr> dir

to list all the persistent images on Hard disk.

2. Now enter:
image_mgr> editjob <image name>

which lists the following image parameters:

3. Scroll down to the required field and edit the settings as required with the

4. Press [Return] to confirm and enter y to save the new value to the default job

NOTE: In some cases, image names can be entered as (*) wildcards; they have a maximum 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].

4 4 4 4 4 4 4 4

eject len(gth): post eject length punch: punch on/off x pos(ition): horizontal image offset on plate y pos(ition): vertical image offset on plate wedge pos(ition): wedge position laser power: not available repeats: not available media name: target media types and size.

cursor keys.

file on the HDD.

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restart
Restarts the processor after a stop. Parameters: [None].

thickness
Sets the plate thickness (microns) for the Processor as follows:

1.10.15 service/medtran menu

The media transport options allow the engineer to move the elevator to a set position and move the plate through the machine.

init
Initialises the media transport software variables, clears any error status settings, 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

4 4 4

0.2 plate: enter 200 0.24 plate: enter 240 0.3 plate: enter 300.

Figure 1.10 Media transport menu (manual and semi-auto)

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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).

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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 contains 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 registration pins. See Volume 3 Section 2.4.5.3 for a description of the setup procedure. 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.

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Parameters: [1 = sets | 0 = clear]

selecting
Sets or clears the internal flag used to indicate that a cassette select operation is in progress. Parameters: [1 = sets | 0 = clear]

returning
Sets or clears the internal flag used to indicate that a cassette is being returned to its shelf. Parameters: [1 = sets | 0 = clear]

xdoor
Shows the status of the X-direction door as open or closed with no parameters entered. Parameter: [None] to simulate the state of the door as either closed or open.

load_cassette
Advances the cassette from the shelf to the plate load position. Parameters: [None]

unload_cassette
Reverses the cassette back from the plate load position to the elevator. Parameters: [None]

display_cassette_status
Displays the cassette position, contents and ID. Parameters: [None].

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.

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1.10.16 service/dbases menu

These options modify the cassette and elevator databases held on the HDD.

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.

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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].

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1.10.17 service/utils menu

nd_char
This utility creates a HDD file called ND_char. The utility sets up characterisation tables of the LPD readings against the ND settings required for exposure calibration. The file is obtained by switching on Y-beam only, setting the resolution at 96 lpmm and measuring the power at the LPD. It is setup at the factory and only needs to be recreated if a laser or the HDD is replaced. For other uses, refer to (Volume 3) Table 4.1 on page 3. During initialisation, the system checks if the file exists, and displays the error code 139 if it is not found. Parameters: [None].

restore_nd_char
Restores the ND Character table to HDD. Enable debug 33 to check operation during the process and disable afterwards. Parameters: [None].

find_lpd_posn
Updates the NVRAM with the new LPD parameter by evaluating and storing the position of the maximum laser power for the LPD. Run this command after replacing the LPD, HDD, SM4 motor or LPD sensor. See Volume 3 Section 4.2.1. Parameters: [Value (-270 to -294]

power_margin
R&D use only.

optics_efficiency
R&D use only.

nd_repeatability
R&D use only.

setup_fpd_offset
Automatically measures the FPD offset and sets up the NVRAM parameter, FPD_OFFSET. Parameters: [None].

1.11 Checking Config and NVRAM Data

1.11.1 Introducing Configuration Data Files
Configuration (Config) data for all the CAN node boards (System board, VBOMB, STB and FHMBs), the overall system and the NVRAM for each board are held on the platesetter as four types of files:
1. 2. 3.

Board Configs: data files (board serial number, etc) for each node board. System Configs: System data (System ID, etc). System Registry: board configuration data that needs to be updated if a hard-

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ware or software change is made.

4. NVRAM: current parameters copied from the System board to the Hard

disk.

The platesetter stores copies of the configuration data files on the System Board and Hard Disk (HDD) as backup data. Useful data for board IDs, revision and history are copied from the Config files and held on a System Registry file that allows service engineers to check and record changes of the system configuration. Figure 1.11 outlines the organisation of the data files and the type of data they store. Service engineers are able to replace node boards with new boards that have different revision levels, download new versions of firmware, update the system registry and run registry checks to ensure that the various versions of hardware and software installed on the system are compatible. If a System board is being replaced, its NVRAM parameters can be copied onto the Hard disk, and restored to the new board, see Section 1.11.7.

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BOARD CONFIG
SERIAL NUMBER BUILD DATE PCB PART No. MACHINE BUILD PCB MANUFACTURER FINAL TEST DATE CHANGES MADE (SYS, F/W, S/W) DETAILS DATE (NOTE) ENGINEER ID

ID DETAILS

MULTIPLE RECORDS (20)

HISTORY DETAILS

NOTE: INCLUDES SYSTEM SERIAL NUMBER OR F/W, S/W USER No.

HDD

SSB

GENERAL\ TMPREG.TXT

CONFIG

FHMB1-4 SOMB

GENERAL\ REGISTRY.TXT

NVRAM

STB
CONFIG

GENERAL\ SYSCONFIG.TXT

SYSTEM REGISTRY

NVRAM

GENERAL\ SYSNVRAM.BIN

SYS CONFIG

SYSTEM CONFIG
SYSTEM ID BUILD DATE TEST DATE SSB SERIAL No. STB SERIAL No. SOMB SERIAL No. FHMB1 SERIAL No. FHMB2 SERIAL No. FHMB3 SERIAL No. FHMB4 SERIAL No. H/W CHANGED DETAILS (NOTE) DATE ENGINEER ID ID DETAILS

MULTIPLE RECORDS (6)

REVISION DETAILS

MULTIPLE RECORDS (10)

HISTORY DETAILS

NOTE: DETAILS OF H/W CHANGED INCLUDING HDD. DETAILS INCLUDE SERIAL No.

Figure 1.11 Configuration and Registry files - structured view

1.11.2 Board Config Files

Each CAN node board (System Board, VBOMB, STB, FHMB1 to 4) stores the following board data (as a maximum number of characters) in a local Board Config file:

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1.11.2.1 ID Data

1.11.2.2 History Data

From each board, Config data is passed to the System Board for storage as sets of multiple records that are displayable as ASCII data. In the case of History records, the last entry is shown first for up to 20 entries. This data can be accessed by the service engineer either for information purposes or for updating whenever the configuration of the board is changed. The current Config data for each board is displayed on a terminal from Main diagnostics after obtaining the Registry menu as follows:
diagnostics> tests sysdiag> registry registry> display_registry board

1.11.3 System Config Files

In addition to the multiple board Config data files, the System Board also holds a similar set of system data files.System config data shows which boards make up the system, allowing the engineer to track board changes. System config data is held separately on the System Board and HDD as the following items:

1.11.3.1 ID Data

1.11.3.2 Revision Data 1.11.3.3 History Data

4 4 4 4 4 4 4 4 4 4 4 4 4 4

serial number (16 chars) build date (5) PCB part number (16) machine build (1) PCB manufacturer (2) final test date (8).

software, firmware and system changes (5) installation dates (8 - taken from the machine Time/Date) installer names. (8 - the password of the installer)

system ID (16 chars) build date (8) tests date (8).

board serial numbers (System Board, STB, FHMB1 to 4, VBOMB)

H/W changed

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For revision data the last 10 system changes are tracked and the last 6 system configurations are stored.

1.11.4 System Registry Files

The System Registry is a set of Config data files for all the node boards in the platesetter and is held on System Board Flash memory, with a copy automatically generated on the HDD. Its purpose is to provide a quick view to the current software, firmware and hardware status of each board, and also the history of any changes made to the software and hardware in the system. Each board has a set of board data files comprising an ID file, a Revision file and a History file, see Section 1.11.4 for details of the ID Data, Revision data and History Data. The History file is automatically updated when the Revision file is changed. Whenever software, firmware or hardware is changed on the system, the engineer must update the System Registry. The next time the system is booted up, the ID, Revision and History files in all of the node boards are compared with the same files in the System Registry by a utility called 'Reg_Powerup' held in the Registry directory. If a difference between any two files is detected, a warning symbol appears (Error Code 1005) on the MMI. This is a non-fatal error allowing the system to continue scanning; however, it will reappear until the registry has been updated using the utility 'Update_Registry', see Section 1.11.7. The current System Registry on the System Board is displayed from Main Diagnostics after obtaining the registry menu:
diagnostics> tests sysdiag> registry registry> display_registry system

1.11.5 HDD Data Files

Hard Disk Drive (HDD) configuration data, held as backup files, is interchangeable with the data on the System Board. Configuration data is held on the HDD in four file areas:
1. 2. 3. 4.

4 4 4

details of change date of change ID of engineer that made the change.

generalmp.txt: temporary data from System Registry on the System Board used for checking compatibility levels after a board or software change. generalegsyslog.txt: a copy of the System Registry on the System Board. generalysconfig.txt: system configuration data from the System Board. generalysnvram.bin: all the NVRAM values from each board are stored via the System Board.

L UXEL P LATESETTER VOLUME 2 (1-65)

NOTE: The registry data held on the HDD will only be different to that stored on the System 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

1.11.6 NVRAM Data

NVRAM values, held by the System Board, are stored for backup on the Hard disk. Engineers can save and restore NVRAM values between the System board and the HDD. The Save and Restore functions are available after obtaining the Configuration menu by entering:
diagnostics> log_utils log_utils> configuration configuration> save _nvram

The Save command takes all the NVRAM board files and copies them to HDD.
configuration> restore _nvram NOTE: Avoid using the command `restore board' unless you are sure the NVRAM configuration on the HDD is the correct version.

1.11.7 Updating the System Registry

If a node board is replaced, or new software is downloaded, then the System Registry data on the System Board and HDD must be updated and checked for hardware/software incompatibilities, see Section 1.11.7.2. This is automatically carried out by the check, Reg_powerup, that automatically runs when the system is booted up after the change. The Reg_powerup test can also be run as an explicit command from:
registry>reg_powerup

The result from this test is either: A compatibility failure shown as an Error Handling screen on the MMI with an Error code of 1005. A pass allowing the MMI scan mode screen to appear. If a software change is made, the registry test is completed and (if successful) allows the system to enter scan mode Where there are non-software changes, then the test will automatically fail requiring the engineer to update the registry using the Update_registry utility, see Section 1.11.7.2. If the System Board or HDD are replaced, data from one device is automatically copied to the new device. However, a problem occurs when both the HDD and System Board are changed. In this case, note the system configuration details and update the registry with the new serial, build and final test data, see Section 1.11.7.2.

VOLUME 2 (1-66) P LATESETTER D IAGNOSTICS

1.11.7.1 Using Display_Registry

1. 2.

Obtain the prompt (registry>) from:

diagnostics/tests/registry

Enter:
registry> display_registry system

for the System Registry

registry> display_registry board

for all the boards.

1.11.7.2 Using Update_Registry

1.

Obtain the prompt (registry>) from:

diagnostics/tests/registry

and enter:
registry> update_registry system

2.

Start to reply to the following set of questions:

Figure 1.12 Update_registry screen 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

1.12 Upgrading Embedded Firmware

New firmware downloads for the application (including diagnostics) and boot files are supplied on a CD disk installed from the RIP server. Use the procedure below:
1.

Make sure you have saved a copy of the current NVRAM settings to HDD in

L UXEL P LATESETTER VOLUME 2 (1-67)

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:

9. Press Select Folder or OK to close the selection window, confirm the selections

10. Restart the platesetter and launch the RIP application. If there have been any

11. Carry out a machine recalibration after changing the firmware. 12. When the machine is working correctly, save the new NVRAM settings

1.13 Setting Up Persistent Images

1.13.1 Creating a PI (Celebrant RIP)
The Engine HDD is able to store diagnostic and calibration PIs selected from the MMI as exposed jobs for customer and service use. These images are persistent

4 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. 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.

when asked, and follow the set of messages that appear as files download to completion. Boot sector changes then a second reboot is necessary.

using the command:

log_utils> save_nvram

VOLUME 2 (1-68) P LATESETTER D IAGNOSTICS

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. 2.

Close the RIP application. Open the File Manager and search for the file `output.cml' from the Windows 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. 5.

Save the file and close down the File Manager. 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. 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.
Image window

6. 7. 8. 9.

Check from the MMI that the image name has appeared on the Run Test in the TOOLS menu. Shutdown the RIP application. Make sure the entered text line in the `output.cml' file is removed or is converted into a comment. To convert into a comment add:
Rem ImageName="xxxxx"

1.13.2 Deleting and Editing a PI (Celebrant RIP)

1.

Enter the following Main Diagnostics menu:

service/disk> dfs

and delete the five files for each PI image: odd, even, id, jd and erl. Use the command rm to remove each file.
2.

To edit a PI, enter:

service/image_mgr> editjob XXXXX

1.13.3 Creating a PI (Rampage RIP)

1. 2. 3. 4.

Edit the environment variable, JOB_NAME, to page name, where the page name is the name of the PI image. Put the page in the plot queue. Note that this page will download to the Engine HDD but will not image. Reset the environment variable to the next page name and follow step 2) above. When all the pages have been downloaded, delete the environment variable,

L UXEL P LATESETTER VOLUME 2 (1-69)

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.

1.14 Running MMI Self-Tests

MMI System Self-tests are run from the TOOLS menu to check devices on all the modules, except for the Processor. These diagnostic tests are described in Section 1.5 on page 1-10. Run the tests as follows:
1. Once the Image Not Downloading icon appears on the TOOLS screen, select
Run Diagnostics

from the menu:

Alternatively, select Run Diagnostics from an Error Handling screen (if the option is active).
2. This function runs all the platesetter System diagnostics and displays a

Splash screen showing the tests running in each of the control sub-systems (node PCBs):

SYSTEM

OPTICS

TRAVERSE

FHMB2 FHMB1

FHMB3

FHMB4

PROCESSOR NOT READY

Figure 1.13 Recorder Self-Tests - diagnosing screen

4 4 4 4 4 4 4

System - System Board check Optics - VBOMB PCB and optics base modules checks Traverse - carriage motors and Traverse PCB checks Elevator - Autofeeder and FHMB2 checks Drum Input - PTM and FHMB4 checks Plate Output - Buffer and FHMB4 checks Drum Output - Module and FHMB1 checks

VOLUME 2 (1-70) P LATESETTER D IAGNOSTICS

3. 4.

1.15 Using Media Tools

1.15.1 Fully-Automatic
Media Tools allows you to select a cassette and output a single unexposed plate for inspection using the following options: advance a single, unexposed plate into the drum eject a single, unexposed plate from the drum swap on-line cassettes feeding the drum park an on-line cassette back into the Autofeeder. Select Media Tools from the PAUSE top-level menu to open the Media Tools screen:
ADVANCE PLATE PARK CASSETTE EJECT PLATE

1.15.2 Manual and Semi-Automatic

Manual and semi-automatic machines have the following media Tools options: advance a single, unexposed plate into the drum eject a single, unexposed plate from the drum swap media types.

Processor - ready/not ready check.

If all the tests pass, then the display shows a Tick icon on the Pass screen

Press Return to reboot and commence scanning. If a self-test fails, the Error Handling screen for the Error Group appears.

ADVANCING PLATE

MEDIA INFO

RETURN

SWAP CASSETTE

Figure 1.14 Media Tools screen (fully-automatic)

L UXEL P LATESETTER VOLUME 2 (1-71)

ADVANCE PLATE

EJECT PLATE

ADVANCING PLATE

MEDIA INFO

RETURN

SWAP MEDIA

Figure 1.15 Media Tools screen (manual and semi-automatic)

VOLUME 2 (1-72) P LATESETTER D IAGNOSTICS

Volume-Chapt er

2-2

PLATE HANDLING CONTROL

This chapter introduces the main plate handling modules and how they control the movement of plates through the system.

2.1 Plate Handling Control Modules

This section briefly introduces the main plate handling control assemblies for all Luxel platesetter variants and shows their approximate location.

2.1.1 Autofeeder
Figure 2.1 outlines the main Autofeeder control assemblies and their connections. 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 forwarding. 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) B)

4 4 4

Plate Handling Control Modules ...............................................................................2-1 Plate Handling Assemblies ......................................................................................2-13 Plate Handling Operation and Sequence ...............................................................2-18

the cassette loading door is open or unlocked the frame travel safety limits at the top and bottom are exceeded.

VOLUME 2 (2-2) P LATE H ANDLING C ONTROL

ZDIRECTION CONTROL MOTOR (BM28)

ELEVATOR MOTOR BM26

DOCKING LIGHT (BV25)

CASSETTE DOOR LOCK (BV22)

A1

ELEV ABS LIMITS (BS68/69)

CASS DOOR LOCK

TO FHMB(2)

MOT DSBLD BS73

BS78

ALARM/ OLOAD (BS74/75)

ELEVATOR CONTROL PCB

BS77

FWD/REV FST/RST (BM26)

+24V

+24V

+24V

+24V

MOTOR CONTROL

CONTACTOR

ELEV CTRL SOL

FILTER

INVERTER E BASE

BM28

BV25

BS72

BV22

BS73

P24V

FHMB(2)

SAFETY RELAY

FHMB(2)

FHMB(2)

FHMB(2)

Figure 2.1 Autofeeder controls and power

See Figure 2.2 Elevator Control PCB: houses a set of relays that switch, under FHMB2 control, to drive the elevator motor drive in the FWD/RST/REV/FAST modes. Elevator Distribution PCB: uses three sensor detectors and three linear vertical vanes (attached to the moving elevator frame) to provide feedback about

MAINS INPUT

CONTACTOR

LOCK

+24V

+24V

BASE

L UXEL P LATESETTER VOLUME 2 (2-3)

the current vertical position of the shelf. Inverter and contactor: the inverter provides power control to the elevator motor, and the contactor halts the motor (BM26) if an interlock signal is received when a cover is opened, or the operator selects the MMI option to open the cassette door. Cassette door lock: a solenoid door lock is under control of the MMI to open the cassette door when installing or removing a cassette. FHMB 2 PCB: the main elevator control PCB linked by the CAN bus to the SSB (System PCB). Sensors: Autofeeder sensors provide feedback to FHMB2 on shelf positions, trolley alignment at the cassette door and the status of the cassette door lock. See also Volume 2 Section 3.2.1.14. Motors: motors (controlled by FHMB2) drive the following plate handling assemblies on the PTM:

Relays and Solenoids: solenoids (controlled by FHMB2) drive the following plate handling assemblies on the PTM:

4 4 4 4 4

AC elevator motor/gear assembly (BM26) - drives the elevator frame Z-direction arm (BM28) - moves the arm up and down cassette door lock (BV22) - opens the cassette door.

Cassette Door Lock (BV22) - locks and unlocks the cassette door Absolute Limit Top and Bottom - indicates limit travel of elevator.

VOLUME 2 (2-4) P LATE H ANDLING C ONTROL

SENSOR VANE ELEVATOR SHELF 5 SHELF SENSING A: YNN B: YYN C: NYN D: NYY 4 E: NNY SENSOR DISTRIBUTION PCB BS31(BOTTOM) ELEVATOR FWD/REV SLOW/RST 3 BS32 2 BS33 BS34 BS30 (TOP)

TOP ABS LIMIT

BOTTOM ABS LIMIT BM26 ELEVATOR MOTOR

BS 74

BS 75

INVERTER CONTACTOR

AC SUPPLY

CASSETTE DOOR LOCK BS 72 BV 22 BS63 ELEVATOR CONTROL PCB CASSETTE DOOR ENTRY BS70 ZDIRECTION ARM BS77 DOCKING LH FHMB2 BS78 DOCKING RH BM28

KEY
BS (SLOTTED) BS (REFLECT) BS (REED) BS (SWITCH) BV (SOLENOID) BM (MOTOR)

Figure 2.2 Autofeeder plate handling control assemblies

2.1.1.1 PTM
Figure 2.3 shows the main control and drive signals to the PTM plate handling devices.

ENGINE (MAINS SUPPLY)

TO AUTOFEEDER ELEVATOR MOTOR CAN5 TO INPUT MODULE AIR KNIFE FAN SENSOR DIST PLATE FEED SENSORS PLATE FEED SENSORS PLATE FEED MOTORS CAN4 CASS ID CASSETTE ID SENSORS CASSETTE FWD/REV SENSORS CASSETTE/X-DIRECTION SENSORS FHMB(2) CASSETTE/X-DIRECTION MOTORS ELEVATOR MOTOR CAN3 ELEVATOR SOLENOIDS (CONTROL PCB) ELEVATOR SENSORS 24V DIST

See Figure 2.4

FHMB(3) EMERGENCY STOPS +24V CONTACTOR

FHMB(4)

ENGINE (PWR DIST)

PWR

Figure 2.3 PTM plate control and drive

FHMB(1)

ENGINE (INPUT SUPPLY)

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 sensor status signals from PTM moving assemblies and provide the 24 V drive to the local motors.

L UXEL P LATESETTER VOLUME 2 (2-5)

ENGINE (SAFETY RELAY)

KEY
BS (SLOTTED) BS (REFLECT) NUDGER AND TAKEAWAY (BM22) FEED HEAD BS (REED) BS (SWITCH) BS46 BS (INDUCTIVE) BV (SOLENOID) BM23 BS45 BM (MOTOR) BS47 BS47

NUDGER LIFT (BM23)

BS46

VIEW ON A

BS45

A
NUDGER BM22 BS43 TAKEAWAY BS51 DIVERTER

VOLUME 2 (2-6) P LATE H ANDLING C ONTROL

BS48

BS43

INPUT ROLLER BS52

CASSETTE AND PLATES BS48 BS49 BS56 BS65 BS50 BS53 BS66 BS57 BS36 40

BV20

BS55 BS59

BM25 CASSETTE ID CASSETTE FORWARD BS44 BS42 BM21 STACK INCREMENT BS61 RETARD INTERLEAF ROLLER

BM24

VACUUM TUBE

BS62

BS71

presence of plates or interleaf paper while the PTM assemblies are operating. See Volume 2 Section 3.3.1.6 for a description of the sensors.

Figure 2.4 PTM plate handling control assemblies

INTERLEAF BIN DOOR BS76

BM27

BS41

X-DIRECTION DOOR

BM20

L UXEL P LATESETTER VOLUME 2 (2-7)

Motors: motors drive the following plate handling assemblies on the PTM:

Relays and Solenoids: drive the following plate handling assemblies:

2.1.2 Imaging Engine

Figure 2.5 shows the main control and drive signals to the Engine plate handling devices. See Figure 2.6. FHMB 1/4 PCBs: provide local control (as firmware routines) for accepting sensor signals and switching plate handling motors on/off. Sensors: Engine sensors are used to determine limits, assembly positions and the presence of plates while Engine assemblies are operating. See also Volume 2 Section 3.4. Motors: motors drive the following plate handling assemblies on the Engine:

4 4 4 4 4 4

X-Direction door (BM27) - moves the door flap up and down when a new cassette is installed. Cassette forward (BM20) - drives the two arms that pulls the cassette into the PTM Stack Increment (BM21) - drives the leadscrew mechanism to increment the stack in small steps to activate the stack height sensor. Nudger and takeaway (BM22) - drives the nudger and takeaway rollers Nudger lift (BM23) - lifts and lowers the nudger roller to remove the top plate on the stack Interleave drive (BM24) - drives the two rollers that push the interleaf paper into a bin.

4 4 4 4 4 4 4 4 4

Air Knife Control (BV23) - switches on/off the air knife

Input module (BM1) - drives the band rollers for conveying plates into the drum. Push bar (BM2) - drives the push bar to forward plates into position for imaging Centering (BM3) - drives the two centering arms for aligning the plate (along the horizontal drum axis) before punching. Punch (BM4) - drives the punch pins. Registration (BM5) - drives the registration pins that operate as a mechanical `stopper' at the leading edge to hold the plate in position for imaging. Output module (BM6) - drives the module rollers for conveying plates out of the drum. Buffer Feed to Processor (BM7) - drives buffer rollers. Plate Centering (BM10) - centres the plate on the manual load platen. Plate Pushing (BM11) - pushes the plate from the platen to the drum.

FHMB PWR FHMB 2/3 VACSOLS/COMPR (BV31) CENTRING/REG/OUTPUT SENSORS

EXT I/LOCK CAN5 FPD FHMB(4) SWING ROLLER SENSORS 24V DIST PUNCH SENSORS REG PIN REG PIN CONT UMBILICAL PUSH BAR SENSORS TRAVERSE CARRIAGE ID1 BUFFER/OUTPUT/ REGISTRATION/ CENTRING MOTORS BUFFER SENSORS SENSOR DIST (O/P)

VOLUME 2 (2-8) P LATE H ANDLING C ONTROL

POWER FILTER PWR2

INTERLOCK BOX

CAN ID

FHMB PWR

SENSOR DIST (I/P)

ID0

PLATE/PUNCH SENSORS INPUT/PUNCH MOTOR

CAN3

SOL 4 (BM41) - controls air blow to the air knife and vacuum blow.

FHMB(1)

BV3

MIXER (EXHAUST)

CAN2 BV8

Figure 2.5 Engine plate control and drive (B1 and B2 fully-automatic)
RTN EXT ALERT RTN

4 4
Swing Roller Motor (BM37) - operates the SRM to hold the leading edge of the plate.

I/LOCKS

L UXEL P LATESETTER VOLUME 2 (2-9)

Solenoids: these drive the following devices:

4 4 4 4 4 4 4

Mixer Fan (BV3) - switches the mixer fan on/off during an expose. Drum Vacuum (BV5) - switches the drum vacuum motor on/off before and after an expose. Error Light (BV8) SOL 1 (Divert Valve - BV 30) - diverts air to the drum. SOL 2 (Compressor relay - BV31) - switches the vacuum compressors on/off. SOL 3 (Leading Edge - BV40) - solenoid for vacuum leading edge. SOL 4 (BV41) - controls air to the vacuum blow and the air knife.

VOLUME 2 (2-10) P LATE H ANDLING C ONTROL

INPUT MODULE PTM BM1 BS52 BS1

OUTPUT MODULE BM6 DRUM BS5

BS4

BS6 BS2 PUSH BAR BM2

PUNCH/ REGISTRATION/ CENTERER MODULE

BM5 (REGISTRATION)

A
BM3 (CENTERER)

BM4 (PUNCH) BS15

BS14 BS12

VIEW ON A BM5 BS3 BM3 BS13

BS8 BS9 BM4

PUNCH/REGISTRATION/CENTERER MODULE (BILLOWS)

KEY
BS (SLOTTED)

B
BS11 BS10 VIEW ON B (UNDERNEATH)

BS (REFLECT) BS (MICRO SW) BV (SOLENOID) BM (MOTOR)

Figure 2.6 Engine plate handling control assemblies (B1 fully-automatic with punch)

L UXEL P LATESETTER VOLUME 2 (2-11)

INPUT MODULE PTM BM1 BS52 BS1

OUTPUT MODULE BM6 DRUM BS5

BS4

BM37 BS6 BS2 PUSH BAR BM2 SWING ROLLER MODULE

BS109/110

REGISTRATION MODULE

BM36 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

No longer includes a labyrinth or height adjuster.

BUFFER EXIT (BS20)

INTERLOCK (B1 MANUAL INTERLOCK IS LINKED OUT)

BUFFER ENTRANCE (BS19)

BUFF_S19/20

BUFF_S19/20

BUFFER FEED TO PROCESSOR (BM7) BUFF_M7

PLATE DIRECTION

ENG_INT

RIB1/2

SENSOR DISTRIBUTION PCB (OUTPUT)

FHMB(4)

CONTROL

CAN

Figure 2.8 Buffer plate control and drive

See Figure 2.9. Sensors: BS19 and BS20 indicate if the Buffer has received a plate and ejected a plate. Motor: BM7 drives the Buffer band roller under control of FHMB4.

IMAGING ENGINE

INTERLOCK BOX

TO SSB

BUFFER

L UXEL P LATESETTER VOLUME 2 (2-13)

BS19

BS20

TO PROCESSOR

BM7 BAND ROLLER

KEY
BS (REFLECT) BM (MOTOR)

Figure 2.9 Plate handling mechanisms and controls - Buffer

2.2 Plate Handling Assemblies

This section describes the standard assemblies used to control the transport of plates for all modules: Plate handling sensors: see Section 2.2.1. Plate handling motor and solenoids: see Section 2.2.2.

2.2.1 Plate Handling Sensors

Plate handling sensors are mainly used to initiate on/off switching for a plate handling motors, indicate a plate jam or check for mechanical limits. There are five types of sensors typically used on the platesetter:
1. Opto-reflective switch: flags the exact position of a plate leading/trailing edge

on the media path.

2. Reflective/diffused: senses reflective light (plate) or diffused light (paper). 3. Opto-slotted switch: detects a limit tab on a motor-driven mechanism. 4. Micro-switch: opens and closes by a moving mechanism. 5. Inductive: detects the metallic or non-metallic presence of plates or paper.
NOTE: The method of removing and replacing these sensors is very similar. A description is given in Volume 3 Section 2.1.1.

2.2.1.1 Opto-Reflective Sensors

These are opto switches which emit light and detect the same light from a reflective surface. The sensor output is +5V when light is reflected back to the detector (reflective plate is present). The sensor output is 0V when light is not reflected (reflective plate is not present). Note that these levels are inverted for software purposes at the sensor registers. Light emitted from opto-reflective sensors used in the plate handling paths are

VOLUME 2 (2-14) P LATE H ANDLING C ONTROL

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 distance. 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 calibration 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) B) C)

Plate Not Detected = LOW output. Plate Detected = HIGH output. 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) B)

Light not Detected = ON Voltage supply: 4.5 to 16 VDC

On fitting opto-reflective sensors, note the following:

1. 2. 3.

As the angle of the sensor to the plate increases, the detection distance reduces. The plate angle for the reflective underside should be >45 with an allowable sensing range of 4 to12 mm. The emulsion side gives a more diffused reflection with a decrease in maximum detection distance. This effect is even more evident with interleaf paper. For emulsion side and interleaf paper, the allowable sensing range is 4 mm to 8 mm.

4.

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 PL1 1 2 3 4 C1 0.1u 25V 4 CATHODE 5 ANODE VCC OUT GND 3 2 1 SW1 EE-SY313

Figure 2.10 Reflective-opto sensor board layout

Paper Plate Sensor PCB:

This PCB is similar to the Reflective-opto PCB and is used to detect the presence of a plate or interleaf sheet. The PCB is calibrated at the factory using an onboard potentiometer. Adjustments should not be made once the device is fitted.

2.2.1.2 Opto-Slotted Sensors

These sensors are used by the software to detect the position of a mechanism, notably for travel limit sensing or position detection. A small vane, fixed to the moving mechanism, interrupts the slot light, indicating to the software the current position of the mechanism. Opto (or interrupt) switches emit and detect light between two integral posts. The sensor output is +5 VDC when light is detected (vane is not interrupting a light beam). The sensor output is 0 VDC when light is not detected (vane is interrupting a light beam).
SUPPLY VOLTAGE GND SLOT FOR FLAG

OUT

Figure 2.11 Opto-slotted sensor connectors (side view)

Voltage supply to the sensor is set at +5 VDC and the type of switching used is:
A) B)

Light not detected = LOW output = read ON. Light detected = HIGH output = read OFF.

VOLUME 2 (2-16) P LATE H ANDLING C ONTROL

2.2.1.3 Reflective/Diffused Sensor

These sensors operate as an integral emitter and a detector for detecting whether light has been reflected from the plate surface (without the interleave paper) or diffused (when the interleaf has failed to be removed). Examples of these sensors are:

Voltage supply to the reflective/diffused sensor is set at +24 VDC. The sensor output is attenuated on the +24 V Distribution PCB before being passed as a +5 V signal to the FHMB. These sensors are setup for correct detection.

2.2.1.4 Micro-switch Sensor

Micro-switches are used to detect a moving assembly and operate as:

2.2.1.5 Magnet Reed Sensor

Two reed sensors inside the Autofeeder cassette door operate when the pin inserts on the trolley buffer locate in the correct position. The sensor includes a 3-way plug:
A) B)

2.2.1.6 Inductive Sensor

An inductive sensor detects either paper (non-metallic) or plate (metallic). After replacing inductive sensors on the PTM follow the instructions on the setup procedure. Voltage supply to the inductive sensor is set at +24 VDC. The sensor output is attenuated on the +24V Distribution PCB before being passed as a +5 V signal to the FHMB. An example of this sensor is:

2.2.2 Plate Handling Motors

2.2.2.1 Stepper Motor
Stepper and 5:1 Gear: A 2-phase unipolar motor used on the push bar. Stepper and 3:1 Gear: A continuous +24 VDC used for the stack increment.

4 4 4 4

4 4 4

BS51 BS55.

Absolute Limit: detects the end of travel at both ends by the Autofeeder frame (trip sensor). Chad tray: detect presence of tray. Cassette at nudger: detects the presence of the cassette at the nudger. Centering detect: left and righthand side.

Pin 2: +24 VDC Pin 3: GND.

BS50.

L UXEL P LATESETTER VOLUME 2 (2-17)

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 interleaf 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.

2.2.2.3 Synchronous Motor

Used to drive the elevator on the Autofeeder.

2.2.3 Plate Handling Solenoids

24 VDC: Used on the push bar latch. Includes 3-w plug

24 VDC Rotary: Used on the diverter, it includes double shaft and return spring.

4 4

pin2 = +24 V pin3 = GND.

VOLUME 2 (2-18) P LATE H ANDLING C ONTROL

2.3 Plate Handling Operation and Sequence

This section describes the operation of each module as plates are conveyed towards the Processor. Refer to Section 2.3.1 for a description of how motors and sensors operate during a plate transfer.

2.3.0.1 Autofeeder Operation

See also Figure 2.2 and Section 2.3.1.1.
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 selections or the operator. Plates are loaded into cassettes in a safelight area and conveyed to the Autofeeder 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, indicating to the system software the media type and size available for each of the downloaded jobs.

2.3.0.2 PTM Operation

See Figure 2.4 and Section 2.3.1.2.
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 increment 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 friction 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 underneath 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)

the sheets underneath.

2.3.0.3 Engine Operation

See Figure 2.6 (fully-automatic with punch) and Section 2.3.1.3. For a description of the vacuum/drum blow system, see Volume 2 Section 7.2.
NOTE: For the description below the terms: LE refers to the Leading Edge of a plate. TE refers to the Trailing Edge of the plate.

Fully-Automatic (with Punch)

See Volume 2 Figure 3.49 showing the main plate handling modules on a drum with a punch and Figure 2.6.

REGISTRATION/ CENTERER

PUSHBAR PUNCH LEAD EDGE VAC

LONG BLOW MAIN VAC SHORT BLOW

Figure 2.12 Drum plate handling modules (with punch)

Fully-Auto, Manual and Semi-Auto (without Punch)

See Volume 2 Figure 3.50 showing the main plate handling modules on a drum without a punch and Figure 2.4. Engine plate sequence depends on whether the plates are large or small. Large B1 (greater than 500 mm high): follow the sequence in Section 2.3.1.4 Small B2 Only (less than 350 mm high): follow the sequence in Section 2.3.1.5. Loading a small plate (B2) causes two problems that are rectified by the deskew and conform sequence:

4 4

the LE of the plate jumps over the registration pins the LE of the plate is scratched if there are drum imperfections.

VOLUME 2 (2-20) P LATE H ANDLING C ONTROL

Ejecting a small plate (B2) causes one problem that is rectified by the deskew and conform sequence:

PUSH BAR

The leading edge (LE) drum vacuum channel at the far output end has three states:
1. 2. 3.

2.3.0.4 Buffer Operation

See Figure 2.9 and Section 2.3.1.6.
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.

small plates tend to jump over the registration pins when conform vacuum is released.

REGISTRATION MODULE

SWING ROLLER MODULE (SRM) LEAD EDGE VAC

LONG BLOW MAIN VAC SHORT BLOW

Figure 2.13 Drum plate handling modules (without punch)

Conform Blow: applied to prevent plate scratching, assist the plate TE into the drum while being pushed, and assist with de-skew continuity. Eject Blow: release the LE of the plate for ejection (at the same time as drum blow occurs for the complete plate). Conform Vacuum: to hold the plate in position for imaging.

L UXEL P LATESETTER VOLUME 2 (2-21)

2.3.1 Plate Handling Control Sequence

This section describes step-by-step how a plate is transported through the platesetter as far as the Processor. For a description of how the Processor operates, refer to the supplied User's Guide. See Figure 2.14 to Figure 2.17 for a flowcart description of plate sequencing for loading, imaging and ejecting. See Volume 2 Section 7.2.3 for a description of the vacuum operation during imaging.

2.3.1.1 At the Autofeeder

See Figure 2.2 for the location of Autofeeder control devices.

Advancing a Cassette into the PTM:

1. Cassette with plate pack is installed onto a shelf and selected from MMI or RIP as active
cassette for loading. Cassette door closes (BS72, cassette door closed), Z-direction arm up (BS63, Zdirection up) and X-direction flap up (BS71, X-direction door up).

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

2.3.1.2 At the PTM

See also Figure 2.4.

1. Stack increment at Home position (BS44 on) and cassette forward in Home position
(BS42, cassette reverse limit). X-direction flap moves down (BM27, X-direction door) and BS71 (X-direction door down).

BM27 BM20 BM21

2. Cassette forward arm (BM20, cassette forward) rotates to pick up cassette.

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)

BS41 (cassette forward limit) actuated indicates an error caused by missing cassette or cassette not installed on shelf. Cassette door on lid opens by ramping up on PTM side plates. Cassette ID read from BS36 to BS40 (cassette ID 1-31).

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).

8. Top LE of plate or interleaf moves (BM22, nudger and takeaway) towards

diverter. BS48 and BS49 are read. If BS48 and BS49 are not detected after timeout, stack is raised slightly (once only). If BS48 and BS49 are still not detected, then an error code is given.

L UXEL P LATESETTER VOLUME 2 (2-25)

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.

2.3.1.3 At the Engine (Fully-Automatic with Punch)

NOTE: This sequence applies to fully-automatic platesetters with a punch using large B1 plates.

See also Figure 2.12.

De-skew and Conform Sequence:

1. Plate LE reaches BS1 (input entrance) and BM1 (friction and band input) moves plate
into drum.

L UXEL P LATESETTER VOLUME 2 (2-27)

Push bar is in Home position (BS6, push bar home).

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)

5. Centering mechanism (BM3, centering) moves fingers inwards from 1174 mm

apart until BS12 (centering RH detect) and BS13 (centering LH detect) are on when contact is made with plate at each side.

Push bar moves forward when electrical continuity between the two centering fingers and plate is detected. Centering fingers move back to Home (BS14, centering home) when plate is centered. An error code is given if the plate cannot be centred.

6. Push bar goes forward again to mechanically conform plate.

Drum vacuum turns on. Punch pins move in (BM4, punch) if required by job (BS8, punch motor in).

VOLUME 2 (2-30) P LATE H ANDLING C ONTROL

7. Push bar moves back 30 mm to clear plate for imaging.

Plate is held by vacuum and mixer fan switches on (BV3). Plate is imaged.

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

2.3.1.4 At the Engine (Non-Punch with Large Plates)

NOTE: This sequence only applies to platesetters without a punch using plates larger than 500 mm (height).

See also Figure 2.7 showing the main plate handling modules on a drum without 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

6. Push bar moves to clear plate for imaging.

Plate is held by vacuum and mixer fan switches on (BV3). Plate is imaged after a plate edge detect is completed at the user end.

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

CONFORM VAC OFF AND EJECT BLOW ON MAIN VAC OFF

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

EJECT BLOW OFF

2.3.1.5 At the Engine (Non-Punch with Small Plates)

NOTE: This sequence only applies to platesetters without a punch using plates smaller than 350 mm (height).

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 problems 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

6. Push bar moves to clear plate for imaging.

Plate is held by vacuum and mixer fan switches on (BV3). Plate is imaged after a plate edge detect is completed at the user end.

Eject Sequence:
7. SRM is down.
Leading edge conform vacuum and main vacuum are switched off.

L UXEL P LATESETTER VOLUME 2 (2-41)

CONFORM VAC AND MAIN VAC OFF

8. SRM is raised and registration pins are retracted.

Leading edge eject blow is switched on and push bar starts to move plate.

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

EJECT BLOW OFF

2.3.1.6 At the Buffer (B1 Variants Only)

See also Figure 2.9.

Feeding a plate into the Buffer and Processor:

1. LE of plate reaches end of output module and BS5 (output exit) is actuated. Buffer band
rollers turn at a faster speed than the output module.

L UXEL P LATESETTER VOLUME 2 (2-43)

LE detected at BS19 (buffer entrance).

BS19 BS5

2. LE of plate reaches end of Buffer and BS20 (buffer exit) is actuated.

Plate is advanced a short distance before BM7 switches off. Buffer waits for Ready signal from Processor.

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.

2.3.1.7 Reversing the Cassette (Fully-Automatic)

See Figure 2.2 and Figure 2.4. This section describes how a cassette is returned to the Autofeeder when a new

VOLUME 2 (2-44) P LATE H ANDLING C ONTROL

type of plate is required.

1. If there is a plate in the drum, it is ejected.

System checks if BS48 (nudger detect) is on or off. If on, the retard pad and nudger roller are lowered. Nudger drive motor reverses until BS48 is off.

2. System checks if BS49 (retard made) is on or off.

If BS49 (and BS48) is on, the system assumes there is still paper at the top of the stack and starts to feed it towards the diverter and waste bin. If instead BS50 (plate at diverter) detects a plate being fed from the stack, the nudger motor reverses and puts the plate back into the stack.

3. Stack increment lowered to Home position (BS44 on), nudger to up (BS46 on)
and Z-direction arm to up (BS63 on).

4. Cassette forward mechanism reverses cassette back onto shelf.

Z-direction arm is down (BS70 on).

L UXEL P LATESETTER VOLUME 2 (2-45)

5. Elevator frame moves to next required position for advancing a cassette.

See Section 2.3.1.1 onwards for a description of how a cassette is forwarded.

2.3.1.8 Recovering from Plate Errors (Fully-Automatic)

See Figure 2.2 and Figure 2.4. An auto-recovery procedure returns the top plate automatically from the feed head to the cassette if there is a fatal error. Note the following:

The purpose of the auto-recovery procedure is to ensure that only the minimum number of plates (one or less) is fogged if the operator has to carry out a manual plate recovery.

1. The MMI displays a fatal Error Handling screen. 2. Retard pad and nudger roller is lowered.

3. Nudger roller (BM22, nudger and takeaway) reverses direction.

Step 2. in Section 2.3.1.7 is completed. If the leading edge of the top plate has not passed BS59 (plate past diverter), it is pushed back into the cassette (that is, a plate recovery procedure is not attempted if the plate is too far into the feeder).

4 4 4

the top plate only returns if the fatal error has been caused elsewhere in the system the cassette is reversed back into the elevator if there is still a plate in the drum then it is ejected.

VOLUME 2 (2-46) P LATE H ANDLING C ONTROL

4. Nudger lifts up and the Z-direction arm moves up.

Stack drops to home position (BS44 on). The cassette forward mechanism reverses direction to push the cassette back into the Autofeeder.

5. If there is a plate in the drum it is ejected to the Buffer.

2.3.2 Plate Handling Flowcharts

Figure 2.14 to Figure 2.17 below show the main sequence of machine steps for loading, imaging and ejecting plates from each of the platesetter variants.

L UXEL P LATESETTER VOLUME 2 (2-47)

Any Jobs to Expose? Yes

No

Check plate pusher and centerer are at Home position

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 WARNING 1248 TIMEOUT_WAITING_FOR_ SUPPORTED_MEDIA When Input Fogging Timer expires give audible alarm. WARNING 1281 MEDIA_FOG_AT_INPUT_ALERT

No Is a plate loaded on the platen (BS118)? Yes Start Input Fogging Timer (6 mins)

Yes Is Autoload ON (Operator Preference)? Yes No Enable "media Confirm" button on MMI.

Has user pressed "Media Confirm"?

Yes Plate centred on Input Platen WARNING 1294 ERR_MEDIA_FEEDER_MEDIA_TOO_BIG or WARNING 1295 ERR_MEDIA_FEEDER_REMOVE_PLATE or WARNING 1296 ERR_MEDIA_FEEDER_REPLACE_PLATE WAIT (Offline Timeout)

Centering is OK? Checks for correct media size Yes

No

No Plate still detected by BS118 on Input Platen? Yes No Drum ready? Yes Plate pushed into Input rollers Clear Input Fogging Timer Plate pusher continues to Home position ERROR 1707

Plate trailing edge at BS1? (Plate is clear of Platen) Yes Centerer guides move to Home position

No

ERROR 1640 or 1600 errors for a device fault

No

Plate trailing edge past BS2?

ERROR 1640 or 1600 errors for a device fault

Yes Plate is now in the Drum Start conforming plate

l Pl t L

dS

Pl t

Figure 2.14 Manual plate load sequence from platen

VOLUME 2 (2-48) P LATE H ANDLING C ONTROL

Edge Detect Expose

Expose is complete Start "processing timer 1". Plate must be processed within 15 minutes

Output rollers empty?

No

If "processing timer " expires WARNING

Yes Tell the Processor the Plate thickness (Semi-Auto only)

Eject plate from drum Clear "processing timer 1"

Plate arrived at output rollers (BS4)?

No

ERROR

Yes

Plate arrived at output rollers (BS5)? Yes

No

ERROR

Manual machine? No, Semi-Auto Yes, Manual Change to Slow speed Start 'Output Fogging Timer' (6 minutes) Move plate to Manual Pick Up position

Change to Slow speed Move plate to 'setter_to_processor' position

No

Plate past o/p rollers entry sensor (BS4)? Yes Processor ready? Yes

ERROR (plate jammed in output)

No

Plate past o/p rollers entry sensor (BS4)? Yes

Wait for operator to remove Plate. Drum is now empty.

Move plate into processor at processor speed Drum is now empty. If 'Output Fogging Timer' expires WARNING 1870 MEDIA_FOG_AT_OUTPUT_ALERT

Plate past o/p rollers exit sensor (BS5)? Yes Output rolelrs are now empty

No

Plate past o/p rollers exit sensor (BS5)? Yes Clear 'Output Fogging Timer' Output Rollers are now empty

Figure 2.15 Plate eject sequence (manual and semi-automatic)

L UXEL P LATESETTER VOLUME 2 (2-49)

Check push bar is in Home position?

Yes De-skew and almost conform plate using push bar

Insert registration pins

Centerer and push bar backs off Check plate in punch sensor (BS3) is clear?

Yes Plate conforms slowly Push bar pushes plate to 30 mm to registration pins (fast operation)

Plate centering is OK? Push bar pushes plate to pins for de-skew (slow operation)

Yes

Vacuum is applied No, try again, but only once Check plate in punch (BS3) is set?

Plate is punched (if required by job ticket) Yes

Push bar backs off 8-10 mm (depends on plate size) Push bar returns to Park position (approx 30 mm before conform area)

Centerer moves nearer to plate. Check for LH sensor.

Imaging starts

Centerer checks LH and RH sensor

Figure 2.16 Plate load and imaging (fully-automatic with punch)

VOLUME 2 (2-50) P LATE H ANDLING C ONTROL

Mixer fan off Loading Blow ON

Push bar postion lookup table

Load plate into drum from Input Module Registration pins ON Push bar Approaches plate Push bar de-skews plate Wait 0.1 sec

Drum+offset(nvram)

Yes

Retry1 < 20 ?

No Initial continuity failed No

Check Reg pin continuity Yes

Final de-skew tapping by push bar Mixer fan on If Plate Height > 350mm Swing Roller Module (SRM) DOWN

ERROR

Step push bar back Push Bar forward Plate Registered to pins If Plate Height < 350mm Swing Roller Module (SRM) DOWN

Yes

Note: Check for continuity after vacuuming. If it fails, try again from the start. If it fails again, continue anyway Retry < 3 ?

No, Continuity failed after SRM moves DOWN Check continuity Yes Loading Blow OFF LE vacuum ON

ERROR

Wait 0.1 sec LE + Main Vacuum ON

Imaging starts Ejection blow ON Wait 1.0 sec (nvram)

Wait 1.5 sec (nvram)

Check continuity

Registration pins OFF Push bar moves to ejection position

SRM moves UP Push bar steps back park position

Ejection blow OFF

Figure 2.17 Plate load and imaging sequence (manual and semi-automatic)

Volume-Chapt er

2-3

PLATE HANDLING MODULES

This section describes the main modules (assemblies) used to transport plates for the Fully-Automatic, Semi-Automatic and Manual systems. It also describes the sensors and motors that operate with the assembly:

3.1 Introducing Plate Handling Modules

See Volume 2 Figure 9.1 showing the main modules for plate handling. This section introduces the main plate handling assemblies fitted on each of the following modules: Autofeeder: see Section 3.2 Plate Transport Module: see Section 3.3 Engine: see Section 3.4 Buffer: see Section 3.5.

4 4 4 4 4 4

Introducing Plate Handling Modules ........................................................................3-1 Autofeeder Plate Handling Modules .........................................................................3-8 Plate Transport Modules ..........................................................................................3-33 Engine Plate Handling Modules ..............................................................................3-61 Buffer Plate Handling Modules..............................................................................3-102 Inter-Module Connections and Control ................................................................3-105

VOLUME 2 (3-2) P LATE H ANDLING M ODULES

3.1.1 Plate Handling Modules and Variants

Table 3.1 lists the all the main plate handling modules for the Luxel platesetter variants.
Table 3.1 Plate handling modules: used on variants B1 Variants Main Modules Fitted on: Fully-Auto (Punch/No Punch Man SemiB2 Variants Fully-Auto (No Punch) Man Semi-

Autofeeder:

Z-Direction Arm Cassette Elevator (with all assemblies) Control Box Assemblies Plate Transport Module: FHMB (2 and 3) Cassette Forward X-Direction Stack Increment Nudger Lift Retard Nudger and Takeaway Interleave Diverter and Drive Transport Plates Guides Antistatic Brush Air Knife Imaging Engine: Input Module Output Module (static tray) Output Module (driven tray) Traverse Registration Module

(NP)

a a a

a a

a a

a a a a a a a a a a a

a a

a a

a a

a a

a a

a a

a a a a a a a a a a a a a a a a a a a a

Trolley

a a a a a

L UXEL P LATESETTER VOLUME 2 (3-3)

Table 3.1 Plate handling modules: used on variants (Continued) B1 Variants Main Modules Fitted on: Fully-Auto (Punch/No Punch Man ual SemiAuto B2 Variants Fully-Auto (No Punch) Man ual SemiAuto

Mechanical Electrical Continuity Edge Detect Punch: Billows New Version Swing Roller Module Transport Pushbar: Spring Pushbar FHMB (1 and 4) Loading Platform (Platen) Chad Assemblies Vacuum System: Compressor Box Valve Cage Sensors Solenoids and Relays Motors Buffer: Roller Transport Sensors Solenoids and Relays Motors

(P)

(P)

3.1.2 Autofeeder
See Table 3.1 for platesetter variant details and Section 3.2 for a module description. The Autofeeder consists of: Trolley: transports cassettes between the safelight loading area and the Autofeeder.

a a a a a

a a a a a

a a a a a

a a a a a

a a

a a a a a

a a a a

a a a a a

a a a a a

a a a a

a a a a a

(NP)

a a a a a

(NP)

a a

a a a a a a a a a a a a a a a a a a

Centering:

(P)

VOLUME 2 (3-4) P LATE H ANDLING M ODULES

Sensors and motors used: BS77, BS78 (Docking). Cassette: consists of a removeable lid with a plate access door that opens automatically as the cassette is advanced towards the PTM. Plates of a single type and size are loaded onto a platen and secured by sliding guides that lock into position. See the Luxel Platesetter Operator's Manual for more information on how to load and install a cassette. Each cassette has a dedicated ID number (from 1 to 31) that is sensed at the PTM as the active cassette for the media and cassette database on the Engine. Sensors and motors used: BM28, BS63, BS70, BM28 (Z-direction); BS 43 (Cassette Empty); BS 36 to 40 (Cassette ID1-5). Elevator: a multi-cassette (5) system uses fixed shelves on an elevator frame that moves up and down under software control. Cassettes are forwarded from the shelf to the feed head assembly as required for a scan job, and reversed back into the shelf when a new plate type is demanded. Shelf positions for software control of elevation are determined by three readhead sensors that detect three vertical vanes, with scaled widths which provide an encoded reading. Sensors and motors used: BS32 to34 (Elevator Shelves); BS 30, BS31 (Elevator Over Top/Bottom); BM26 (Elevator). Z-direction Arm: in a vertical position it operates as a constraining arm to align the cassette to the PTM entry; in a horizontal position it allows access for the cassette to be pushed onto a shelf. It indicates an error if the cassette is not fully pushed in during the shelf install procedure. Sensors and motors used: BS63, BS70 (Direction Up/Down), BM28 (Z-Direction). Control Assemblies: Elevator control is from FHMB 2 and the local Elevator Distribution/Control PCBs.

3.1.3 Plate Transport Module

See Table 3.1 for variant details and Section 3.2 which describes the PTM modules in more detail X-direction Door: this is a flap that moves up to the vertical position when the cassette is installed into the Autofeeder. In the up position, it ensures the cassette follows the shelf runners during a load from the trolley; when down, it allows access to the PTM feed head. The door remains down until a new cassette is installed. Sensors and motors used: BS62, BS71 (Direction Door Down/Up), BM27 (Xdirection Door). Cassette Forward: collects the cassette from the elevator shelf and pulls it towards the feed head; also reverses the cassette back into the shelf. Sensors and motors used: BS41, BS42 (Cassette Forward/Reverse), BS65 (Cassette at Nudger); BM20 (Cassette Forward). Stack Increment: raises the plate stack until BS47 is actuated. If the nudger mis-feeds, it raises the stack in increments of 0.1 mm before the first plate is nudged.

L UXEL P LATESETTER VOLUME 2 (3-5)

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

Sensors and motors used: BS1, BS2 (Input Entrance/Exit). Drum: the drum allows the plate to be held and conformed before imaging. A plate is pushed round the lower circumference of the drum by the push bar as far as the registration pins, centered and then punched. Drum vacuum holds the plate in position while scanning occurs. Vacuum grooves on manual and semi-automatic drums have a leading edge and main vacuum zones. Sensors and motors used: BS1, BS2 (Input Entrance/Exit); BM1 (Friction and Band Input). Punch Mechanism (B1 fully-auto only): these are a bridge-type punch that allow the plate to pass through after the registration pins are retracted. Punch build versions for Violet machines are currently New Billows. The punch protocol configuration (Heidelburg, Komori, etc) depends on customer preferences. On fully-automatic machines, the punch mechanism is combined with the centering and registration mechanism as a single replaceable module. Later machines may include the Fuji punch with design modifications to improve chad removal. Sensors and motors used: BS8, BS9 (Punch Motor On/Off), BS3 (Plate in Punch); BM4 (Punch). Centering Mechanism (B1 fully-auto only): centres the plate inside the punch by moving two fingers from the Home position towards each other until the sensor on each finger makes contact with the plate. Mechanical centering only occurs on B1 fully-automatic machines with a punch; all nonpunch machines rely on the edge detect function to ensure the plate is not skewed and the image is started at the correct traverse offset. Sensors and motors used: BS12, BS13 (Centering Detect), BS14 (Centering Home); BM3 (Centering). Registration Mechanism (B1 fully-auto only): a set of motor-activated pins that stop a plate in a reference position for imaging and punching. The pins are withdrawn to allow the passage of the plate to the output module. Sensors and motors used: BS10, BS11 (Registration Motor In/Out); BM5 (Registration Pins Motor). Registration Module (non-punch only): stop the plate in a reference position for imaging. A lack of electrical continuity between the two registration pins and the plate indicates plate skew. An additional Registration Pin Board sets the voltage for electrical continuity. Sensors and motors used: BM36 (Registration Pins), BS100 (Registration Pin Motor Home), BS103 (Registration Pin Motor In). Edge Detect PCB: locates the precise position of the plates horizontal edge in order to determine the start of image position. Swing Roller Module: holds the plate leading edge against the drum surface for imaging. Registration Pin Isolation PCB: used by the plate centering system to isolate the two registration pins from chassis ground. Sensors and motors used: BS104 (Registration Pin Continuity).

L UXEL P LATESETTER VOLUME 2 (3-7)

FHMB (1 and 4): provides control for the engine plate handling mechanisms. 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 forward to the output module and then returns to the Home position. Two version 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 synchronise 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

3.2 Autofeeder Plate Handling Modules

.The Autofeeder consists of a frame cage, control assemblies and an elevator with five cassette shelves that move up and down as a cassette plate type is selected for forwarding. Assemblies are divided between: Control - see Section 3.2.1. Mechanical - see Section 3.3.2.

3.2.1 Autofeeder Control Assemblies

See Figure 3.1. Overall control of the Autofeeder and elevator movements is from FHMB2, with AC motor drive fed through the PTM from the Engine.

TROLLEY DOCKING INDICATOR

ELEVATOR DISTRIBUTION PCB

Z-DIRECTION ARM

CASSETTE DOOR LOCK SOLENOID

ELEVATOR CONTROL PCB

CONTROL CABLES TO PTM

ABSOLUTE SAFETY SWITCH (UPPER)

POWER CONNECTION TO MOTOR

ELEVATOR CONTROL BOX

MOTOR ABSOLUTE SAFETY SWITCH (LOWER)

GEARBOX

Figure 3.1 Autofeeder controls - location of main control assemblies

L UXEL P LATESETTER VOLUME 2 (3-9)

A separate interlock mechanism ensures AC power to the elevator motor is switched off when:
A) B)

the cassette loading door is open or unlocked frame travel safety limits at the top and bottom are exceeded.

Control assemblies are: Elevator Control Box - the box includes:

Elevator Interlock Controls. Elevator Control PCB. Elevator Distribution PCB. Cassette Door - the cassette door includes:

Z-Direction Arm. Absolute Safety Switch. Motors and Gears Solenoids. Sensors.

3.2.1.1 Elevator Control Box

Elevator motor control assemblies are housed in a control box shown in Figure 3.1 and Figure 3.2.

4 4 4 4 4

RFI Filter Inverter. Contactor.

Cassette Door Lock Solenoid. Trolley Docking Indicator.

VOLUME 2 (3-10) P LATE H ANDLING M ODULES

MOTOR CONTROL CHASSIS

COOLING FINS

TERMINAL BLOCK

FILTER

DIN RAIL

INVERTER (SJ100)

END STOP SURGE SUPPRESSOR CONTACTOR

Figure 3.2 Elevator control box assemblies (filter/inverter/contactor)

3.2.1.2 RFI Filter

See Figure 3.3. An RFI filter is used to suppress inverter spikes in both directions. This is because the inverter is a switching module that generates external noise which could affect motor control and outside equipment.

L UXEL P LATESETTER VOLUME 2 (3-11)

NEUTRAL MAINS SUPPLY AUTOFEEDER BASE EARTH LIVE EARTH FILTER

L TO INVERTER CONTROLBOX PLATE CONTROL BOX LID N

PLATE EARTH POINT

EARTH

MOTOR

Figure 3.3 RFI Filter connections

3.2.1.3 Inverter
An Hitachi SJ100 inverter uses a set of four switched relays on the Elevator Control PCB (see Section 3.2.1.6) to control multispeed power sequencing for the elevator 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/overload conditions are set.

VOLUME 2 (3-12) P LATE H ANDLING M ODULES

When running, the inverter generates considerable heat that is dissipated by a rear cooling fin. Make sure the module is properly ventilated and the covers are not blocked. All switching relays on the Elevator Control PCB are supplied from +24 V generated from the inverter.
a) ELEVATOR RED OR YL ALARM GND BLK ACCESS: OPEN FRONT PANEL L H 6 0 ALARM I/P WH/BLU 5 01 4 L 3 FM 2 CM2 1 12 P24 11 BLK WHT ACCESS: BEHIND FRONT PANEL BLK AL1 AL0 BLU WHT/BLU ALARM I/P ALARM I/P BRN BLU&WH (2 WIRES) RST FAST REV FWD P24V TO ELEVATOR CONTROL PCB (PL4)

O/LOAD (BS75) ALARM (BS74) ALARM CONTROL

b) ELEVATOR POWER ACCESS: LOOSEN M4 SCREW TO OPEN CASE L1 L2 L3/N T1/U T2/V T3/W BLK L (BRN) N (BLU) BR BL BLK BLK TO CONTACTOR

MAINS SUPPLY (FROM FILTER O/P)

Figure 3.4 Inverter connections (control/power)

L UXEL P LATESETTER VOLUME 2 (3-13)

Error Codes
The inverter shows a set of error codes to indicate the state of the motor circuit.
Table 3.2 Inverter error code conditions
Error Type Displayed Code 01 to 04 Error Comment

Over Current

Output of inverter is shorted, motor is locked or the load is too heavy. Inverter switches off. Motor overload is detected causing thermal trip. Inverter switches off. Overvoltage is detected and inverter switches off. Motor overvoltage is detected and inverter switches off. Memory has an error due to noise or temperature. Inverter switches off. Decrease in input voltage to a certain cut off point. Inverter switches off. Large noise source too close to the inverter. Inverter switches off. CPU malfunctions. Inverter switches off. Abnormal signal from external equipment causes inverter to switch off. Power is turned on while the inverter is running. Ground fault detected between inverter output and motor. Input voltage is above a certain limit. Inverter output is switched off. Temperature of inverter is too high because cooling fan has failed. Inverter is switched off. External thermistor is too large. Inverter switches off when PTC function is selected. Inverter receiving voltage has dropped so output is off.

Overload

E 05

Braking Overload Overvoltage Protection EEPROM Error

E 06 E 07 E 08

Undervoltage

E 09

CT Error

E 10

CPU Error External Trip

E 11 E 12

USP Error Ground Fault Input Overvoltage Protection Thermal

E 13 E 14 E 15

E 16

PTC Error

E 17

Waiting

---U

VOLUME 2 (3-14) P LATE H ANDLING M ODULES

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 (FROM INVERTER) BRN BLU WHT RD BS73 (TO ELEV CONTROL PL1) +24V (TO ABS LIMIT)

21 NC

A1

CONTACTOR

22 NC

A2

BLU TO MOTOR BRN WHT

BLK WHT/OR

+24V RTN BS73

(TO ELEVATOR CONTROL PCB PL1)

Figure 3.5 Contactor connections

3.2.1.5 Elevator Interlock Controls

See Figure 3.6. Autofeeder control ensures that a local contactor removes power to the elevator motor when: one of the elevator absolute limit switches is tripped by the elevator passing the upper/lower safety limits of travel cassette door is unlocked or open an interlocked cover is open. See also Volume 2 Figure 9.10 for an overall view of the interlock system, including the control assemblies on the Engine.

L UXEL P LATESETTER VOLUME 2 (3-15)

KEY COIL

DOOR LOCK +24V CONTACTOR A1 21 DOOR LOCK NC BS 72

BV22 FHMB(2) SAFETY RELAY FHMB(2)

SURGE SUPPRESSOR

BV22

x2

SCHMERSAL SOLENOID LOCK

A2 LOCK RTN

22 BS72 TO FHMB(2)

ABS LIMIT TOP

(BS68)

LIVE NEUTRAL EARTH

MAINS INPUT

ABS LIMIT BOTTOM

(BS69)

FILTER

L U

N V

E W

NOTES: FHMB(2) SIGNALS VIA ELEVATOR CONTROL PCB INVERTER (BS74/75) FHMB(2) SEE ALSO SECTION 11.2.4.4 FOR INTERLOCKS CONTROL

A1

21 NC CONTACTOR BS73

A2

2 U

4 V

6 W

22 BS73 TOFHMB(2) GEAR MOTOR (ELEVATOR)

FHMB(2) +24V RTN

Figure 3.6 Elevator interlocks - schematic view

VOLUME 2 (3-16) P LATE H ANDLING M ODULES

3.2.1.6 Elevator Control PCB

Figure 3-3.7 shows the Elevator Control PCB layout.

PL3

ELV_CTRL (FWD/REV/ETC)

SK1

PL2

PL4 ELV_IN

PL1 ELV_CTRTL (BS73)

Figure 3.7 Elevator Control PCB - layout view

Location
Mounted on the frame on the service side, see Figure 3.1.

Elevator Control Connectors

PL1: PL2: PL3: PL4: SK1: ELV_CTRL. Not Used. Not Used. ELV_CTRL. 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 (PL4) REV/FAST/ RST/FWD 6 2

BM2 (SK1 SOL1-4 RTN

BM26 (FWD/REV/FST/RST) RELAY (SW2) +24V 1 4 ALARM_H

INVERTER CONTROL (PL4) ALARM 2 BS74 RELAY (SW1) +24V 1 4 OLOAD_H 6

SK1

ALARM_L

INVERTER CONTROL (PL4) OVERLOAD 2 BS75 6

SK1

OLOAD_L

Figure 3.8 Elevator control relays - pin arrangement

VOLUME 2 (3-18) P LATE H ANDLING M ODULES

3.2.1.7 Elevator Distribution PCB

Figure 3.9 shows the PCB layout.

SENSOR VANE BS31

BS32

BS33

BS34 BS30 PL5

PL1

PL2

PL3

PL4

Z-DIRECT (UP)

Z-DIRECT (DOWN)

RIB8

ELV_LOCK

Figure 3.9 Elevator Distribution PCB - layout view

Location
Mounted on the elevator sensor vane bracket, see Figure 3.1 and Figure 3.16.

Elevator Distribution Connectors

PL1: PL2: PL3: PL4: PL5: Not used. Not used. ELV_LOCK (Z-Direct UP) ELV_LOCK (Z-Direct Down) 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

SAFETY LIMIT VANE CODE: 001

ELEVATOR DISTRIBUTION PCB AND SENSORS

101

SENSOR VANE

SHELF E

Figure 3.10 Sensor vane reading (5 shelves)

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 sensor, 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 alignment is set during the installation using a specification and an alignment procedure.

VOLUME 2 (3-20) P LATE H ANDLING M ODULES

You can check the operation of the elevator sensors using the read_sensor command Main Diagnostics.

Table 3.3 Shelf and sensor encoding Shelf A (top) B C D E Sensor 34 OFF OFF ON ON ON Sensor 32 ON OFF OFF OFF ON Sensor 33 ON ON ON OFF OFF

3.2.1.8 Cassette Door Lock Solenoid

See Figure 3.1 and Figure 3.11. A Schmersal safety lock (AZM170) operates from a solenoid (BV22) that is released under software control for installing/removing the cassette. While the door is in use, a switch sensor (BS72) indicates the status of the lock to the SSB. The door has an actuating key that locks under MMI control.

DOOR AND KEY RED BK

OR

BS72 12 11 A1

BV22 A2 WH

RED

22 SCHMERSAL SOLENOID LOCK (AZM170-02Z)

21

GN

Figure 3.11 Cassette door lock - lock wiring

3.2.1.9 Trolley Docking Indicator

See Figure 3.1 and Figure 3.12. A docking indicator is used by the operator to ensure that the trolley is correctly aligned (square) with the cassette door before the cassette is installed into the Autofeeder. Two magnetic reed switches (BS77 and BS78) on both sides of the cassette door are made when both trolley buffer inserts are detected. This sensor circuit is in series with the docking lamp to enable a +24V supply.

L UXEL P LATESETTER VOLUME 2 (3-21)

TROLLEY AND INSERTS

BS78 SWITCH +24V

BS77 SWITCH

DOCK LAMP RTN

Figure 3.12 Docking indicator control

3.2.1.10 Z-Direction Arm

See Figure 3.13. A mechanical Z-axis arm with a guide roller is used to constrain the cassette while it is loading into the PTM. Its position UP or DOWN) also indicates to the software if the cassette is correctly installed before advancing. This mechanism uses a dc motor/worm gear and wormwheel to move the arm.
M6 SCREW

GUIDE ROLLER

WORMWHEEL SPACER BS63 SENSOR

Z-AXIS ARM

BEARING RETAINER

BEARING

BRACKET

MOTOR (BM28) BS70 SENSOR

COVER BRACKET

Figure 3.13 Z-direction control assembly

VOLUME 2 (3-22) P LATE H ANDLING M ODULES

3.2.1.11 Absolute Limit Safety Switch

See Figure 3.1. Two safety switches (upper limit and lower limit) are set to disable the elevator if it travels beyond an upper and lower safety point. The switches are in series with the interlock supply to the contactor which switches off the elevator motor, see Figure 3.6. Once switched, the sensor must be reset by pulling out its yellow button. These switches are a final hardware limit to the elevator travel in either direction; normally, a software travel limit check will indicate an error before the switch is triggered.
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 assembly from the Autofeeder.

3.2.1.12 Autofeeder Motors

The two Autofeeder motors (BM) are as follows: BM26 Elevator Location: see Figure 3.1. Type: asynchronous motor and two-stage gearbox. Operation: raises and lowers the elevator. BM28 Z-Direction Control Location: see Figure 3.1 and Figure 3.13. Type: DC Operation: moves up an arm, checks that a cassette is fully home and that restrains the cassette while it is being pulled into the PTM.

Elevator Motor/Gearbox (BM26)

Elevator drive is from an asynchronous motor with a two-stage worm gearbox. The gearbox is sealed and does not require maintenance.
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 chapter are also used to raise or lower the elevator.

3.2.1.13 Autofeeder Solenoids

Figure 3.1 shows the location of all the Autofeeder solenoids (BV) as follows: BV22 Cassette Door Lock Location: above the cassette door. Type: solenoid Operation: unlocks a door to allow a plate cassette to be loaded into the Autofeeder.

L UXEL P LATESETTER VOLUME 2 (3-23)

BV25

Docking Light Location: located above the cassette door, see Section 3.1. Type: green lamp Operation: controls supply to a lamp indicating that the trolley and cassette is aligned correctly to the Autofeeder.

3.2.1.14 Autofeeder Sensors

The location, type and operation of all the Autofeeder sensors are as follows, see Figure 3.1: BS30 Elevator Top Limit Location: rear of sensor distribution PCB. Type: opto-slotted (wide). Operation: indicates the elevator at the top limit position. BS31 Elevator Bottom Limit Location: rear of sensor distribution PCB. Type: opto-slotted (wide). Operation: indicates the elevator at the bottom limit position. BS32 Elevator Shelf 1 Location: rear of sensor distribution PCB. Type: opto-slotted (wide). Operation: positioning shelf detector, binary 1. BS33 Elevator Shelf 2 Location: rear of sensor distribution PCB. Type: opto-slotted (wide). Operation: positioning shelf detector, binary 2. BS34 Elevator Shelf 3 Location: rear of sensor distribution PCB. Type: opto-slotted (wide). Operation: positioning shelf detector, binary 4. BS63 Z-Direction Up Limit Location: inside the cassette door, righthand side. Type: opto-slotted. Operation: detects when the Z-direction arm is raised. BS70 Z-Direction Down Limit Location: inside the cassette door, righthand side. Type: opto-slotted. Operation: detects when the Z-direction arm is lowered. BS72 Cassette Door Closed Location: inside of the cassette door lock.

VOLUME 2 (3-24) P LATE H ANDLING M ODULES

Type: switch inside the Schmersal lock assembly. Operation: monitors state of the cassette door and returns a signal to the System PCB. BS73 Elevator Motor Disabled Location: part of elevator contactor. Type: part of contactor. Operation: monitors the state of the elevator contactor for removing power to BM26 if the cassette door or an interlocked door is opened, see Figure 3.6. BS74 Vector Drive Alarm Location: detected from the inverter, see Figure 3.8. Type: inverter detector circuit. Operation: vector drive output status from the inverter to stop the elevator. BS75 Vector Drive Overload Location: detected from the inverter, see Figure 3.8. Type: inverter detector circuit. Operation: vector drive output status from the inverter to stop the elevator. BS77 Docking Made (RH) Location: inside the cassette door (RHS) and fitted to trolley buffer, see Figure 3.1. Type: reed switch. Operation: detects correct right-hand side engagement of trolley and switches on docking light if BS78 is also actuated. BS78 Docking Made (LH) Location: inside the cassette door (LHS) and fitted to trolley buffer, see Figure 3.1. Type: reed switch. Operation: detects correct left-hand side engagement of trolley and switches on docking light if BS77 is also actuated.

3.2.2 Autofeeder Mechanical Assemblies

The main cassette/plate handling assemblies on the Autofeeder, shown in Figure 3.14 are: Main Frame - includes:

Elevator Frame - includes: Sensor Vane.

4 4 4

Multi-cassette Housing. Cassette Loading Door

L UXEL P LATESETTER VOLUME 2 (3-25)

Elevator Drive Assemblies - includes: Trolley. Cassette.

BRACKET/CAM FOLLOWER CASSETTE LOADING DOOR

Figure 3.14 Main frame assemblies (without elevator frame and multi-cassette housing)

3.2.2.1 Main Frame Assemblies

A main outer frame, shown in Figure 3.14, houses the control modules and mechanical assemblies. The Autofeeder base locates the anchor feet and jacking castors at each corner. The castors are only used to manoeuvre the module; the weight of the module is always distributed on four anchor feet that are locked in position with the castors lifted. Two floor restraints, at the outer ends of the main frame, prevent the Autofeeder from moving when the trolley is pushed against the cassette door. Check that the restraint brackets are securely fixed to the floor.

3.2.2.2 Multi-Cassette Housing Assembly

The housing assembly sits on top of the Autofeeder frame to allow room for raising the elevator. A single version of the housing is available for a 5-shelf frame. Once fitted, it is not normally removed for a service procedure, unless

Elevator Motor, Gear and Drive Shaft.

JACKING SCREW JACKING PIN

FOOT ADJUSTER

ELEVATOR CONTROL BOX BASE

DRIVE SHAFT MOTOR GEARBOX FLOOR RESTRAINT BRACKET

VOLUME 2 (3-26) P LATE H ANDLING M ODULES

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.

3.2.2.3 Cassette Loading Door

This door can only be opened from the MMI using the `Change Cassette' options. See Section 3.2.1.8 which describes the door locking mechanism.

3.2.2.4 Elevator Frame

Figure 3.15 shows the main sub-assemblies fitted on the elevator frame: Sensor Vane Elevator Drive Assemblies. A cam follower bracket aligns the elevator frame to the main frame and the PTM. The alignment is factory-set. An adjustable bracket allows the follower setting to be altered on either side, but this is only required if there is a problem levelling all the shelves to the cassette guides on the plate feed.
ELEVATOR FRAME WALL (DETAIL REMOVED)

ELEVATOR SENSOR VANE AND DISTRIBUTOR PCB (SEE FIGURE 5.22)

CASSETTE LOADING ROLLER

CAM FOLLOWER BRACKET

SHELF

CAM LOCATION CHANNEL BASE CHAIN PLATE

Figure 3.15 Elevator frame assemblies

L UXEL P LATESETTER VOLUME 2 (3-27)

3.2.2.5 Sensor Vane

See Figure 3.15 and Figure 3.16. The sensor vane is fixed to the elevator frame and moves through sensors fitted on a PCB attached to a fixed bracket.

ELEVATOR DISTRIBUTOR PCB (ATTACHED TO FRAME BRACKET )

ELEVATOR SENSOR VANE

Figure 3.16 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.

3.2.2.6 Elevator Drive Assemblies

The elevator frame is moved up/down by a gearmotor and chain pulley arrangement shown in Figure 3.17. Each drive chain is identified with its number of links. As an extra safety feature, the chains run on gear sprockets with metal guard plates that ensure they engage with the sprockets if the tensioner spring suddenly fails. The guard is factory-set and should not be adjusted.

VOLUME 2 (3-28) P LATE H ANDLING M ODULES

IDLER SHAFT (SHORT)

IDLER SPROCKET

CHAIN (195) CAM AND BRACKET CHAIN (189) ELEVATOR DISTRIBUTION PCB ABSOLUTE LIMIT UPPER SENSOR

IDLER SHAFT (LONG)

CHAIN (119) SPROCKET BEARING CHAIN PLATE & TENSIONER (FIGURE 5.24) ELEVATOR MOTOR (BM26)/ GEAR

CHAIN (119)

CHAIN GUARD CHAIN ADJUSTER (FIGURE 5.24)

DRIVE SHAFT GEAR ABSOLUTE LIMIT LOWER SENSOR

SENSOR VANE

Figure 3.17 Elevator drive assemblies

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 elevator frame. This is a replaceable part.

L UXEL P LATESETTER VOLUME 2 (3-29)

BUSH

TENSIONER SPRING PIN LINK ASSEMBLY

SPLIT PIN PULL OUT TO REMOVE

LINK PLATE

MORE LINKS

Figure 3.18 Drive chain tensioner linking

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 loading 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 PIVOT TRAY SPACER ROLLER LATCH STRIKER PLATE PIVOT BRACKET HANDLE LATCH ASSEMBLY

LATCH ACTUATOR ROD

BUFFER HANDLE SUPPORT

BRAKE

FRAME ASSEMBLY CASTOR

Figure 3.19 Trolley assemblies - detail view

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)

CASSETTE REAR LID

SNAP CATCH CASSETTE FRONT LID

Figure 3.20 Cassette lid assembly

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, cassette 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 HANDLE ADJUSTMENT PLATE (FACTORY SET) (LH LOWER) NOTE: CENTERING DOWELS, CASSETTE SHELF BALLS AND FORWARD CHANNELS ARE UNDERNEATH

LIGHT SEAL GASKET

BUFFER LABYRINTH BUFFER CORNER

ADJUSTMENT PLATE WASHER

Figure 3.21 Cassette body assembly

SHORT PLATE GUIDE

PLATE AT DATUM EDGE

SCALE LONG PLATE GUIDE CLAMP HANDLE

Figure 3.22 Cassette platen assembly

L UXEL P LATESETTER VOLUME 2 (3-33)

3.3 Plate Transport Modules

The PTM consists of: Control assemblies - see Section 3.3.1 Mechanical assemblies - see Section 3.3.2.

3.3.1 PTM Control Assemblies

The main control modules on a PTM are: FHMB PCB (2). FHMB PCB (3). PTM Distribution PCBs. PTM Motors PTM Solenoids and Relays. PTM Sensors. Air Knife and Control Assemblies.
CASS ID PCB SENSOR DISTRIBUTION PCB 24V DISTRIBUTION PCB FHMB 2

SENSOR DISTRIBUTION AND 24V DISTRIBUTION PCBs

FHMB 3

Figure 3.23 Location of main PTM control assemblies

VOLUME 2 (3-34) P LATE H ANDLING M ODULES

Two FHMBs (2 and 3) control the plate handling devices for the PTM and Autofeeder. 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.

3.3.1.1 FHMB PCB (2) Assembly

See Figure 3.24 showing the PCB layout and also Volume 1 Section 2.2.1 describing how the FHMB functions.
PL7 PL9 PL12 PL14 PL24 PL25 PL26 PL21 PL23 FS14

PL19 PL18

SK3

PL30

PL6 SK2 PL11 PL5

FS13

PL29

FS12

SK1

PL28 FS15

PL4

FS11

PL3 PL13 PL2 PL1

PL17 PL27

FS1

PL31

FS2 PL8

PL10
FS3

PL15 PL16 FS4 FS5 FS6

FS7

FS8

PL20

PL22 FS9

FS10

Figure 3.24 Motor PCB FHMB (2) layout

L UXEL P LATESETTER VOLUME 2 (3-35)

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: PL2: PL3: PL4: PL5: PL6: PL7: PL8: PL9: PL10: PL11: PL12: PL13: PL14: PL15: PL16: PL17: PL18: PL19: PL20: PL21: PL22: PL23: PL24: PL25: PL26: PL27: PL28: PL29: 8-way male Molex header type STR 6410. See Table 3.4. 2-way male Molex 6410 straight header. Not used. 4-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. Not used. 6-way male Molex straight header. Not used. 8-way male Molex minifit Jr. Not used. 4-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. See Table 3.4. 8-way male AMP CT straight header. See Table 3.4. 3-way male AMP CT straight header. See Table 3.4. 10-way male boxed header. Not used. 4-way male AMP CT straight header. Not used. 10-way male boxed header. Not used. 8-way male AMP CT straight header. See Table 3.4. 3-way male AMP CT straight header. See Table 3.4. 3-way male AMP CT straight header. See Table 3.4. 40-way male boxed header. Not used. 26-way male header. RIB7 cable connection to Elevator Distribution PCB. 26-way male straight header. RIB6 cable connection to Box Cassette ID PCB. 3-way male AMP CT straight header. See Table 3.4. 4-way male AMP CT straight shrouded header. Not used. 3-way male AMP CT straight header. See Table 3.4. 4-way male AMP CT straight header. See Table 3.4. 4-way male AMP CT straight header. See Table 3.4. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. See Table 3.4. 6-way male single in-line shrouded header top entry. Not used. 6-way male single in-line shrouded header side entry. Not used. 6-way male single in-line shrouded header top entry. Not used.

VOLUME 2 (3-36) P LATE H ANDLING M ODULES

PL30: PL31: SK1: SK2: SK3:

6-way male single in-line shrouded header top entry. Not used. 8-way Molex minifit Jr. PWR3 power connection. 15-way female D-type. CAN3 bus connection from FHMB (1). 45-way female R/A boxed header. Not used. 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: FS2: FS3: FS4: FS5: FS6: FS7: FS8: FS9: FS10: FS11: FS12: FS13: FS14: FS15: U33: U39: U42: U43: U27 TP1: TP2: TP3: TP5: TP6: TP8: TP9: 2A for Elevator Control 2.5A. for Cassette Door Closed. 2.5A. Spare. 2.5A for Docking Light. 2.5A for Elevator Reset. 4 A. Spare 4A. Z-Direction Control. 2.5A for X-Direction Door. 2.5A. Spare. 2.5A for Cassette Door. 2.5A. Not used. 2.5A. Not used 2.5A. Not used. 2.5A. Not used. 2.5A. Spare. Electronic Programmable Logic Device. Controls and reads sensors. Electronic Programmable Logic Device. Solenoids and DC motors. Electronic Programmable Logic Device. Stepper motors. Electronic Programmable Logic Device. Controls and reads sensors. Firmware. CAN Ground. Pulsed drive to opto-reflective sensors. CAN +5V. A-D Converter Ground. A-D Converter +5V. Digital Ground. System Reset. Out of Reset = virtually zero volts when measured from TP23.

Main ICs

Test Points

L UXEL P LATESETTER VOLUME 2 (3-37)

TP13: TP16: TP17: TP18: TP20: TP22: TP23: TP24: TP30: TP31: TP32: TP33: TP34:

+24V Ground. Digital Ground. Pulsed drive to opto-reflective sensors. +5V supply to DC motor drivers. Digital Ground. Sensor Latch 2. Digital Ground. +5V Digital supply rail. Unprotected 5V. +24V. +24V Ground. +24V Ground. +24V Ground.

FHMB (2) Motor, Solenoid, Relay and Sensor Distribution PCBs

Table 3.4 FHMB (2) Distribution PCB devices Device ID Motors: BM20 BM26 BM26 BM26 BM26 BM27 BM28 Cassette Forward Elevator - Fast Elevator - Fwd Elevator - Rev Elevator - Reset X-Direction Door Z-Direction Door 22 1 1 1 15 20 16 Not Used Not Used Not Used Not Used Not Used Not Used Not Used Device Description FHMB (2) Plug No Distribution PCB

Solenois and Relays: BV22 BV25 Sensors: BS30 BS31 BS32 BS33 BS34 BS36 Elevator Over Top Elevator Over Run Bottom Elevator Shelf 1 Elevator Shelf 2 Elevator Shelf 3 Cassette ID 1 18 18 18 18 18 19 Elevator Dist Elevator Dist Elevator Dist Elevator Dist Elevator Dist Cass ID Cassette Door Lock Docking Light (Indicator) 8 10 Not Used Not Used

VOLUME 2 (3-38) P LATE H ANDLING M ODULES

Table 3.4 FHMB (2) Distribution PCB devices Device ID BS37 BS38 BS39 BS40 BS41 BS42 BS62 BS63 BS65 BS70 BS71 BS72 BS73 BS74 BS75 BS76 BS77 BS78 Device Description Cassette ID 2 Cassette ID 3 Cassette ID 4 Cassette ID 5 Cassette Forward Limit Cassette Reverse Limit X-Direction Door Up Z-Direction Up Limit Cassette at Nudger Z-Direction Down Limit X-Direction Door Down Cassette Door Closed Motor Disabled Vector Drive Arm Vector Drive Overload Front Door Open Docking Made RH Docking Made LH FHMB (2) Plug No 19 19 19 19 19 19 9 18 23 18 19 14 14 24 26 19 18/21 18 Distribution PCB Cass ID Cass ID Cass ID Cass ID Cass ID Cass ID Not Used Elevator Dist Not Used Elevator Dist Not Used Not Used Not Used Not Used Not Used Cass ID Not Used Not Used

FHMB (2) Motor, Solenoid, Relay and Sensor Variants

Table 3.5 FHMB (2) Variants: control device fitted Device Fitted All devices in Table 3.4 above Variants All Fully-Automatic machines

3.3.1.2 FHMB PCB (3) Assembly

See Figure 3.25 showing the PCB layout and also Volume 1 Section 2.2.1 describing how the FHMB functions.

L UXEL P LATESETTER VOLUME 2 (3-39)

PL7

PL9

PL12

PL14

PL19 PL18

PL24 PL25 PL26 PL21 PL23 FS14

SK3

PL30

PL6 SK2 PL11 PL5

FS13

PL29

FS12

SK1

PL28 FS15

PL4

FS11

PL3 PL13 PL2 PL1

PL17 PL27

FS1

PL31

FS2 PL8

PL10
FS3

PL15 PL16 FS4 FS5 FS6

FS7

FS8

PL20

PL22 FS9

FS10

Figure 3.25 Motor PCB FHMB (3) layout

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: PL2: PL3: PL4: PL5: PL6: PL7: PL8: PL9: 8-way male Molex header type STR 6410. See Table 3.6. 2-way male Molex 6410 straight header. Not used. 4-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. Not used. 6-way male Molex straight header. Not used. 8-way male Molex minifit Jr. Not used. 4-way male AMP CT straight header. See Table 3.6. 3-way male AMP CT straight header. Not used. 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. 3-way male AMP CT straight header. See Table 3.6. 10-way male boxed header. Not used. 4-way male AMP CT straight header. See Table 3.6. 10-way male boxed header. Not used. 8-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. See Table 3.6. 3-way male AMP CT straight header. See Table 3.6. 40-way male boxed header. Not used. 26-way male header. RIB4 input from pulsed sensor inputs via Vertical Distribution PCB. See Table 3.6. 26-way male straight header. RIB5 input from pulsed sensor inputs via 24V Distribution PCB PCB. See Table 3.6. 3-way male AMP CT straight header. See Table 3.6. 4-way male AMP CT straight shrouded header. Not used. 3-way male AMP CT straight header. See Table 3.6. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 6-way male single in-line shrouded header top entry. Not used. 6-way male single in-line shrouded header. Not used. 6-way male single in-line shrouded header top entry. See Table 3.6. 6-way male single in-line shrouded header top entry. Not used. 8-way Molex minifit Jr. PW3_INT connection. 15-way female D-type. CAN4 connection from FHMB (2). 45-way female R/A boxed header. Not used. 15-way female D-type. CAN5 connection to FHMB (4).

PL10: PL11: PL12: PL13: PL14: PL15: PL16: PL17: PL18: PL19: PL20: PL21: PL22: PL23: PL24: PL25: PL26: PL27: PL28: PL29: PL30: PL31: SK1: SK2: SK3:

L UXEL P LATESETTER VOLUME 2 (3-41)

Connector Pin Descriptions

See Figure 9.8 showing system cable interconnections.

Fuses
FS1: FS2: FS3: FS4: FS5: FS6: FS7: FS8: FS9: FS10: FS11: FS12: FS13: FS14: FS15: U33: U39: U42: U43: TP1: TP2: TP3: TP5: TP6: TP8: TP9: TP13: TP16: TP17: TP18: TP20: TP22: 2A for Platefeeder Pump/24V for sensor. 2.5A. Not used. 2.5A. Spare. 2.5A for Diverter. 2.5A for Interleave Drive. 4 A. Spare. 4A. Retard Drop. 2.5A for Nudger and Takeaway. 2.5A. Spare. 2.5A for Nudger Lift. 2.5A. Not used. 2.5A. Not used. 2.5A. for Stack Height. 2.5A. Not used. 2.5A. Not used. Electronic Programmable Logic Device. Controls and reads sensors. Electronic Programmable Logic Device. Solenoids and DC motors. Electronic Programmable Logic Device. Stepper motors. Electronic Programmable Logic Device. Controls and reads sensors. CAN Ground. Pulsed drive to opto-reflective sensors. CAN +5V. A-D Converter Ground. A-D Converter +5V. Digital Ground. System Reset. Out of Reset = virtually zero volts when measured from TP23. +24V Ground. Digital Ground. Pulsed drive to opto-reflective sensors. +5V supply to DC motor drivers. Digital Ground. Sensor Latch 2.

Main ICs

Test Points

VOLUME 2 (3-42) P LATE H ANDLING M ODULES

TP23: TP24: TP30: TP31: TP32: TP33: TP34:

Digital Ground. +5V Digital supply rail. Unprotected 5V. +24V. +24V Ground. +24V Ground. +24V Ground.

Motor, Solenoid, Relay and Sensor Controls

Table 3.6 FHMB (3) distribution PCB devices Device ID Motors: BM21 BM22 BM23 BM24 BM25 Stack Height Nudger and Takeaway Nudger Lift Interleave Drive Retard Drop 29 20 22 15 16 Not Used Not Used Not Used Not Used Not Used Device Description FHMB (3) Plug No Distribution PCB

Solenoids and Relays: BV20 BV23 BV24 Sensors: BS43 BS44 BS45 BS46 BS47 BS48 BS49 BS50 BS51 BS52 BS53 BS55 BS56 Cassette Empty Stack Height Home Nudger Down Limit Nudger Up Limit Stack Height Position Nudger Detect Retard Made Plate at Pre Diverter Paper Post Diverter Park Position Pre Input Nip Paper Tensioner (Lazy Loop) Paper Post Diverter Retard Up 18 12 19 19 18 18 18 19 19 18 18 19 18 Sensor Dist Not Used 24V Dist 24V Dist Sensor Dist Sensor Dist Sensor Dist 24V Dist 24V Dist Sensor Dist Sensor Dist 24V Dist Sensor Dist Diverter Air Knife Fan (Relay) 24V for Sensor On/Off 10 1 1 Not Used Not Used On 24V Dist

L UXEL P LATESETTER VOLUME 2 (3-43)

Table 3.6 FHMB (3) distribution PCB devices (Continued) Device ID BS57 BS59 BS61 BS66 Device Description Retard Down Plate Past Diverter Stack Height Top Limit Interleave Nip Clear FHMB (3) Plug No 18 19 7 19 Distribution PCB Sensor Dist 24V Dist Not Used 24V Dist

Table 3.7 FHMB (3) Variants: control device fitted Device Fitted All devices in Table 3.6 above Variants All Fully-Automatic machines

3.3.1.3 PTM Distribution PCBs

A set of distribution PCBs optimise machine cable runs between each PTM sensor device and its handling FHMB. There are three Distribution PCBs on the PTM: Sensor Distribution PCB New 24V Distribution PCB Cassette ID PCB. Figure 3.26 shows the PCB mounting arrangement on the service side of the PTM.

SENSOR DISTRIBUTION PCB

24V DISTRIBUTION PCB

FEEDER END PLATE (PTM SERVICE SIDE)

Figure 3.26 Distribution PCB mounting arrangement (PTM)

Sensor Distribution PCB

Figure 3.27 shows the layout of the Sensor Distribution PCB for a fully-automatic platesetter and Figure 3.23 shows its location on the PTM. The PCB sup-

VOLUME 2 (3-44) P LATE H ANDLING M ODULES

plies +5V to each of the sensors and returns signals to FHMB 3.

BS43 PL1 BS48 PL5 BS49

BS52

PL2

PL3

PL4 RIB4/RIB5

BS56

PL6

PL7 PL10

PL8

BS57

PL9

PL11

PL12

BS47

BS53

Figure 3.27 Sensor Distribution PCB (FHMB 3) - layout view

24 V Distribution PCB (New)

Figure 3.28 shows the layout of the New 24V Distribution PCB for a fully-automatic platesetter and Figure 3.23 shows its location on the PTM. This PCB distributes +24 VDC to energise the following sensors on the PTM: BS50 (plate in pre-diverter) BS51 (paper post-diverter top) BS55 (paper post-diverter bottom). Pin connection power for the 24 V sensor plugs are:
A) B)

pin 2 = +24 V pin 4 = 0 V.

It also distributes +5 VDC to energise the following sensors on the PTM: BS45: (nudger down limit) BS46: (nudger up limit) BS59: (plate past diverter) BS66: (interleave nip clear). Pin connection power for the 5 V sensor plugs are:
A)

pin 2 = +5 V

L UXEL P LATESETTER VOLUME 2 (3-45)

B)

pin 3 = 0 V.
BS51 (FHMB3) BS3 (FHMB4)

BS50 24V I/P PL8

SET CAN ID 1

PL11

BS55 (FHMB3) BS18 (FHMB4) PL3

PL5 PL2 PL1 PL4

PL7

PL12 PL10 FHMB (PL19)

PL6

PL9

BS46

BS45

BS66

BS59

Figure 3.28 New 24 V Distribution PCB (FHMB 3) - layout view

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 cassette 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 BS42 PL2 BS41 PL4 PL3 PL1

PL5

PL6

VIEW ON OPTO-REFLECTSWITCHES

SW5 (ID5) BS40 SW3 (ID3) SW2 (ID2)

SW4 (ID4) BS39 SW1 (ID1)

BS38

BS37

BS36

Figure 3.29 Cassette ID PCB (FHMB 2) - layout view

3.3.1.4 Motor Assemblies and Operations

The location and operation of all the PTM motors (BM) are listed as follows: BM20 Cassette Forward Location: see Figure 3.32. Type: DC with braking. Operation: pulls and pushes the cassette in and out of the elevator. BM21 Stack Height (Increment) Location: see Figure 3.34. Type: stepper with 3:1 gearbox. Operation: raises and lowers plate stack to nudger rollers. BM22 Nudger and Takeaway Location: see Figure 3.35. Type: DC (33 rpm). Operation: drives top plate off the cassette. BM23 Nudger Lift Location: see Figure 3.35. Type: DC (33 rpm) with braking. Operation: tilts the nudger assembly. BM24 Interleave Drive Location: see Figure 3.38.

L UXEL P LATESETTER VOLUME 2 (3-47)

Type: DC (66 rpm) with one-way clutch. Operation: drives the paper bin rollers. BM25 Retard Drop Location: see Figure 3.37. Type: DC (33 rpm) with braking. Operation: pulls down the retard pad mechanism. BM27 X-Direction Door Location: see Figure 3.31. Type: DC. Operation: raises and lowers the cassette guide door.

3.3.1.5 PTM Solenoids and Relays

PTM solenoids/relays (BV) are listed as follows: BV20 Diverter Location: see Figure 3.38. Type: solenoid. Operation: lowers diverter when the plate is detected; springs back up when power is removed. BV23 Air Knife Fan Location: service side, below air knife fan assembly. Type: relay. Operation: controls the +24 VDC switching supply for the air knife. BV24 24 Volt for Sensor On/Off Location: on New 24 V Distribution PCB. Type: relay. Operation: controls the switching of +24 VDC to BS50 and BS51.

3.3.1.6 PTM Sensors

The location of all the PTM sensors (BS) are listed as follows: BS36 Cassette ID1 Location: see Figure 3.23. Type: opto-reflective Operation: cassette ID1, binary 1. BS37 Cassette ID2 Location: see Figure 3.23. Type: opto-reflective Operation: cassette ID2, binary 2. BS38 Cassette ID3 Location: see Figure 3.23. Type: opto-reflective

VOLUME 2 (3-48) P LATE H ANDLING M ODULES

Operation: cassette ID3, binary 4. BS39 Cassette ID4 Location: see Figure 3.23. Type: opto-reflective Operation: cassette ID4, binary 8. BS40 Cassette ID5 Location: see Figure 3.23. Type: opto-reflective Operation: cassette ID5, binary 16. BS41 Cassette Forward Limit Location: see Figure 3.32. Type: Opto-slotted. Operation: stops the motor in the clockwise direction. BS42 Cassette Reverse Limit Location: see Figure 3.32. Type: opto-slotted. Operation: stops the motor in the anti-clockwise direction. BS43 Cassette Empty Location: see Figure 3.35. Type: opto-reflective Operation: detects if the cassette is empty. BS44 Stack Height (Increment) Home Location: see Figure 3.34. Type: opto-slotted. Operation: detects when the plate lifter is at Home (i.e. down). BS45 Nudger Down Limit Location: see Figure 3.35. Type: Opto-slotted. Operation: monitors the position of the cam on BM23. BS46 Nudger Up Limit Location: see Figure 3.35. Type: opto-slotted. Operation: monitors the position of the cam on BM23. BS47 Stack Height (Increment) Position Location: see Figure 3.35. Type: opto-slotted. Operation: stops BM21 when the plate stack reaches position.

L UXEL P LATESETTER VOLUME 2 (3-49)

BS48

Nudger Plate Detect Location: see Figure 3.35. Type: opto-reflective. Operation: indicates a plate has been pulled from the cassette to the nudger.

BS49

Retard Made Location: see Figure 3.39. Type: opto-reflective. Operation: indicates that the plate is now in the takeaway roller nip.

BS50

Plate at Pre-diverter Location: see Figure 3.39. Type: Inductive. Operation: Indicates either paper or plates (+24 V supply).

BS51

Paper Post Diverter (Top) Location: feed head cross bar, attached to hinge and bracket above guide plate, see Volume 3 Figure 2.10. Type: reflective/diffused (+24 V supply). Operation: checks for plate or paper. The device operates as an integral emitter and a detector that senses light reflected from the plate surface (without the interleave paper) or diffused (when the paper has failed to be removed). See Volume 3 Section 2.3.2.2 for the setup procedure if this sensor is replaced.

BS52

Park Position Pre-Input Nip Location: see Figure 3.39. Type: opto-reflective Operation: indicates that the next plate is ready.

BS53

Paper Tensioner (Lazy Loop) Location: see Figure 3.38. Type: micro-switch. Operation: monitors paper tension and stops the interleave drive rollers for a period if actuated.

BS55

Paper Post Diverter (Under) Location: see Figure 3.39. Type: Reflective/diffused (+24 V supply). Operation: checks for plate or paper. The device operates as an integral emitter and a detector that senses reflected light from the plate surface (without the interleave paper), or diffused light (when the paper has failed to be removed). See Volume 3 Section 2.3.2.1 for the setup procedure if this sensor is replaced.

BS56

Retard Up Location: see Figure 3.37.

VOLUME 2 (3-50) P LATE H ANDLING M ODULES

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)

3.3.2 PTM Mechanical Modules

See Figure 3.30 showing the arrangement of the main assemblies. The main plate handling assemblies feed plates from the cassette to the Engine drum and divert paper interleaf sheets to a waste bin. Once the cassette is installed (in the Z-direction) on the Autofeeder, these assemblies advance and reverse cassettes (in the X-direction) between the feed head and the Autofeeder elevator. X-Direction Door. Cassette Forward. Stack Increment. Feed Head. Retard Pad. Interleaf Diverter/Drive Roller. Plate Guides.
INTERLEAF DIVERTER X-DIRECTION DOOR ASSEMBLY

FEED HEAD ASSEMBLY RETARD PAD ASSEMBLY

CASSETTE FORWARD ASSEMBLY INTERLEAF DRIVE ROLLER ASSEMBLY STACK INCREMENT ASSEMBLY

Figure 3.30 Plate handling assemblies - general view

3.3.2.1 X-Direction Door

See Figure 3.31. The complete assembly is removed to access the sensors and motor. The assem-

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bly consists of:

A)

motor and worm gear: drives the flap up (cassette install) or down (cassette advance) flap and box section: the flap ensures the cassette is correctly aligned inside the elevator. sensors and vane: a vane rotates into two sensors to indicate the up/down position of flap for the application software.
PIVOT BLOCK SENSOR BRACKET UP SENSOR BS71 SENSOR BS62 FOLDED FLAP R. H. SUPPORT BRACKET

B)

C)

MOTOR MOUNTING BRACKET

SENSOR VANE FOLDED BOX SECTION

SENSOR BRACKET DOWN

MOTOR BM27

Figure 3.31 X-Direction door - detail view

3.3.2.2 Cassette Forward Cassette Forward Assembly

See Figure 3.32. The complete assembly is removeable to access the sensors, motor and drive belts. The assembly consists of:
A)

Drive arm with cam follower: rotates to advance/reverse the cassette between the elevator and the feed head. Top plate: holds the assembly to the PTM mounting frame. Eccentric idler: provides the belt tension. Sensor plate and sensors: limit sensors to control arm travel for forward and reverse directions. Motor and gear: secured by a motor support plate.

B) C) D)

E)

L UXEL P LATESETTER VOLUME 2 (3-53)

F)

Belt and pulleys: a set of drive/idler pulleys move a timing belt and drive arms.

LH ARM ASSEMBLY BEARING BLOCK RH ARM ASSEMBLY BELT FORWARD SHAFT ECCENTRIC IDLER/TENSIONER DRIVE PULLEY MOTOR SUPPORT PLATE

DRIVE ARM

BEARING AND CIRCLIP

CAM FOLLOWER NOTE: TOP COVERING PLATE REMOVED IN THIS DIAGRAM

DRIVE ARM SENSOR PLATE SENSOR TAB

A
GEAR

VIEW ON ARROW A IDLER

MOTOR BM20

SENSOR BS42

IDLER/ TENSIONER SENSOR BS41

Figure 3.32 Cassette forward assembly - detail view

Cassette Forward Operation

See Figure 3.33. Volume 2 Section 2.3 explains how the cassette forward mechanism operates. The two arms advance/reverse the cassette as follows: As the two arms rotate in the advance direction, the cams locate inside the cassette grooves to pull in the cassette to the feed head. As the two arms rotate in the reverse direction, the cams push the cassette

VOLUME 2 (3-54) P LATE H ANDLING M ODULES

back into the elevator. The drive arms rotate 270 from their home position to collect the cassette from the elevator shelf by sliding cam followers into the cassette channels and pulling the unit forward. After the cassette at nudger (BS65) sensor indicates the cassette has reached the feed head the drive arms stop rotating. A reverse rotation pushes the cassette back into the elevator, as shown in Figure 3.33.

CASSETTE REVERSE DIRECTION

CASSETTE FEED POSITION

CASSETTE ADVANCE DIRECTION

HOME

HOME

CASSETTE FORWARD TOP PLATE

CASSETTE ADVANCE DIRECTION

CASSETTE REVERSE DIRECTION

CASSETTE FEED POSITION

Figure 3.33 Cassette forward arm direction

3.3.2.3 Stack (Height) Increment

See Figure 3.34. The complete assembly is removed to access the sensors, motor and drive belts. The assembly consists of:

L UXEL P LATESETTER VOLUME 2 (3-55)

Lift bar: lifts the cassette feed end. Leadscrew: drives the lift bar in increments. Drive pulleys and timing belts: two belts (1500 and 410 length) connect at a double pulley. Idler pulley: provides tension for 1500 belt. Motor and gears: motor on the support bracket provides 410 belt tension. Sensors: for the top limit and home positions of the lift bar.
MOTOR (BM21) AND GEARBOX SENSOR BS61 BEARING (LEADSCREW AND DRIVE SHAFT) SENSOR BS44 STACK LIFT

LIFT BAR

BEARING BLOCK

BELT (T5/410) MOTOR SUPPORT

SENSOR BRACKET BELT (T5/1500) ECCENTRIC PIN STACK IDLER PULLEY IDLER BRACKET

DOUBLE PULLEY

Figure 3.34 Stack Increment assembly - detail view

3.3.2.4 Feed Head

See Figure 3.35. The assembly consists of: Motors: one motor lifts the nudger and the other drives the nudger/takeaway rollers. Nudger lift mechanism: operate as a cam that pushes down on the bar to lift/ drop the nudger roller. A load bar weight provides the friction force for nudging the plate. Stack height mechanism: adjusted to set the correct position of the plate stack for nudging. Takeaway mechanisms: chain drive for the two rollers with tension provided by the sliding motor fixings. Support plates: set of plates retaining the feed head mechanisms.

VOLUME 2 (3-56) P LATE H ANDLING M ODULES

MULTI SENSOR SUPPORT BRACKET

SENSOR BS46 (NUDGER UP LIMIT)

MOUNTING SCREW SENSOR BS47 (STACK HEIGHT POSITION)

ADJUSTING SCREW (M5) STACK HEIGHT SENSOR ADJUSTING BRACKET SUPPORT BACKPLATE R. H. END PLATE FEED HEAD INTERFACE PLATE DO NOT TOUCH SCREW FIXING

NUDGER LIFT SENSOR VANE L. H. END PLATE NUDGER LIFT CAM

SENSOR BS48 (NUDGER DETECT)

SENSOR BS45 (NUDGER DOWN LIMIT)

SENSOR BS43 (CASSETTE EMPTY) NUDGER LOAD BAR BUSH STRIP TENSION ROLLER ROLLER AXLESHORT ROLLER CHAIN

PLATE HEIGHT SENSOR VANE ROLLER AXLELONG DRIVE ROLLER CHAIN

MOTOR BM22

Figure 3.35 Feed Head - detail view

3.3.2.5 Antistatic Brush

An antistatic brush support assembly is fitted on the feed head support backplate to remove static from paper sheets as they pass through to the de-interleaver.
SUPPORT BACKPLATE FEED HEAD

ANTISTATIC BRUSH SUPPORT ASSEMBLY

Figure 3.36 Antistatic brush

L UXEL P LATESETTER VOLUME 2 (3-57)

3.3.2.6 Retard Pad

Figure 3.37 shows the retard pad assembly which consists of: Pad: operates from a cam, shaft and actuating lever mechanism to raise and lower the pad. A stainless steel paper guide (with black PE tape) forms an ramp between the retard pad and the lead edge guide to prevent paper sheets from binding on the retard pad.
PAPER GUIDE RETARD DOWN CAM MOTOR AND GEAR BM25

SPRING LOCATOR SENSOR BS57

LEAD EDGE GUIDE RETARD PAD

SPRING

MOTOR PILLAR

SENSOR BS65

FRONT VIEW ADJUSTING SCREW

SENSOR BS56

MOUNTING SCREWS

LEAD EDGE GUIDE

PAPER GUIDE

MOUNTING PLATE RETARD PAD

END PLATE SENSOR BS57 SENSOR BRACKET

ACTUATING LEVER CENTERING PIN VIEW SHOWING RETARD BACKPLATE REMOVED

SENSOR BS65

CAM SHAFT RETARD DOWN CAM SENSOR VANE MOUNTING SCREWS DO NOT TOUCH SENSOR BS56 RETARD INTERFACE

Figure 3.37 Retard assembly - detail view

Spring locators and adjusters: the pad has a factory-adjusted spring mechanism 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 microswitch 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.

3.3.2.7 Interleaf Diverter and Drive Roller

Figure 3.38 shows the interleaf diverter and drive roller assemblies. The diverter and drive rollers are two separate assemblies consisting of: Diverter guide: normally in the up position for interleaf sheets. Solenoid: drops the diverter guide for plates. It includes a coupling between the device and the guide shaft. Counter-weight: enables the guide to rise to its home position for interleaf sheets. A new longer counter-weight is now fitted. Rollers: drive roller and nip roller. Bearings: these are not FRUs but they are removable.
ROTARY SOLENOID BV20

SOLENOID COUPLING

STEADY ROLLER DIVERTER GUIDE AND SHAFT BEARING RETAINER BEARING MOTOR/GEAR BM24 PAPER TENSIONER BS53 NIP ROLLER STEADY BRACKET

DRIVE ROLLER COUNTERBALANCE WEIGHT RETAINER END PLATE COUNTERBALANCE BLOCK

ROLLER TUBE

Figure 3.38 Interleaf diverter and drive rollers - detail view

L UXEL P LATESETTER VOLUME 2 (3-59)

3.3.2.8 Plate Transport Guides

See Figure 3.39. The five plate guides are designed to be easily removed to access assemblies on the PTM which require a service procedure. They provide a smooth travel surface for transferring plates (driven by the takeaway motor) from the cassette to the input module. The guides are stationary plates fixed between the feed head and the input module to provide a path for the plates and interleaf sheets. An air knife assembly blows any surface contaminants back towards the Autofeeder. Two Mylar deflection strips (short and long) are attached to the feed head with adhesive backing. They are fitted to ensure that plates stay in contact with the guides and activate sensor BS50.

VOLUME 2 (3-60) P LATE H ANDLING M ODULES

PRE-DIVERTER GUIDE (LH) FIXING BRACKETS (LH)

DIVERTER SOLENOID BV20

SENSOR BS50 SENSOR BS49 FIXING BRACKETS (RH)

POST-DIVERTER

SENSOR BS52

DIVERTER PRE-DIVERTER GUIDE (RH)

SENSOR BS55

SENSOR BS59 ENGINE INTERFACE AIR KNIFE ASSEMBLY

A
COUNTER WEIGHT PRE-DIVERTER GUIDES ROUTE TO VALVE CAGE (BV41) POST-DIVERTER

BRACKET

DIVERTER

AIR KNIFE ASSEMBLY ENGINE INTERFACE

SENSOR BS49 SENSOR BS50 PRE-NIP

BRUSH

MOTOR 24V DC INTERLEAF LOWER GUIDE (1) DRIVE ROLLER INTERLEAF LOWER GUIDE (2) VIEW ON ARROW A

Figure 3.39 Transport guides plates - assembly views

L UXEL P LATESETTER VOLUME 2 (3-61)

3.4 Engine Plate Handling Modules

The Engine consists of: Control assemblies - see Section 3.4.1 Mechanical assemblies - see Section 3.4.2.

3.4.1 Engine Control Assemblies

Fully-Automatic: control and power from the Engine are routed to the Buffer and PTM (and Autofeeder), see Volume 2 Figure 9.8. Note that the Engine must be mechanically coupled with the PTM to avoid plate `fogging'. The Buffer forms a bridge to the Processor ensuring there is no risk of light `fogging' plates. Manual and Semi-Automatic: Engine and Buffer control and power is the same as the fully-automatic for these variants.
NOTE: differences in control assemblies depend on whether the system is without a punch (web) or with a punch.
24V DISTRIBUTION PCB

MMI PCB

SENSOR DISTRIBUTION PCB (OUTPUT)

FHMB 4

REGISTRATION PINS OPTO ISOLATOR PCB

SENSOR DISTRIBUTION PCB (INPUT) FHMB 1

DRUM

NOTE: TRAVERSE PCB's NOT SHOWN SEE CHAPTER 2-5 RFI BOX

FAST PHOTO DETECT

Figure 3.40 Location of engine plate control PCBs (fully-automatic)

VOLUME 2 (3-62) P LATE H ANDLING M ODULES

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.

3.4.1.1 FHMB PCB (1) Assembly

Figure 3.41 shows the PCB layout.

FHMB (1) Location

Mounted inside the Engine, on the service side (see Figure 3.40).

FHMB (1) LEDs and Links

There are no LEDs or links.

FHMB (1) Connectors

See Table 3.8 listing cable plug/socket connections to FHMB (1). See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing FHMB (1) cable interconnections. PL1: PL2: PL3: PL4: PL5: PL6: PL7: PL8: PL9: PL10: 8-way male Molex header type STR 6410. 2-way male Molex 6410 straight header. 4-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. Not used. 6-way male Molex straight header. Not used. 8-way male Molex minifit Jr. Not used. 4-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. 8-way male AMP CT straight header. Not used. 3-way male AMP CT straight header.

L UXEL P LATESETTER VOLUME 2 (3-63)

PL11: PL12: PL13: PL14: PL15: PL16: PL17: PL18: PL19: PL20: PL21: PL22: PL23: PL24: PL25: PL26: PL27: PL28: PL29: PL30: PL31: SK1: SK2: SK3:

10-way male boxed header. Not used. 4-way male AMP CT straight header. Not used. 10-way male boxed header. Not used. 8-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. 3-way male AMP CT straight header. 40-way male boxed header. Not used. 26-way male header. RIB3 to Sensor Distribution PCB (Input). 26-way male straight header. 3-way male AMP CT straight header. Not used. 4-way male AMP CT straight shrouded header. Not used. 3-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. BS80 Mixer fan detect. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 6-way male single in-line shrouded header top entry. Not used. 6-way male single in-line shrouded header side entry. Not used. 6-way male single in-line shrouded header top entry. Not used. 6-way male single in-line shrouded header top entry. BM11 Plate pusher (Man). 8-way Molex minifit Jr. FHMB_PWR power supply 15-way female D-type. CAN2 from LSB. 45-way female R/A boxed header. Not used. 15-way female D-type.CAN3 to FHMB92) for fully-automatic/CAN to FHMB(4) for manual and semi-automatic.

FHMB (1) Connector Pin Descriptions

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing FHMB(1) cable interconnections and Volume 2 Section 8.1 listing cable connections and signals.

FHMB (1) Fuses

FS1: FS2: FS3: FS4: FS5: FS6: FS7: FS8: FS9: 2A for Mixer fan and remote Alert. 2.5A. Not used. 2.5A. Spare. 2.5A. Not Used. 2.5A for Friction and Band Input motor. 4 A. Spare. 4A. Punch motor. 2.5A. Not used. 2.5A. Spare.

VOLUME 2 (3-64) P LATE H ANDLING M ODULES

FS10: FS11: FS12: FS13: FS14: FS15:

2.5A. Not used. 2.5A. Not used. 2.5A. Not used. 2.5A. Not used. 2.5A. Not used. 2.5A. Spare.
PL9 PL14 PL12 PL24 PL25 PL26 PL21 PL23 FS14

PL7

PL19 PL18

SK3

PL30

PL6 SK2 PL11

FS13

PL29 PL5

FS12

SK1

PL28 FS15

PL4

FS11

PL3 PL13 PL2 PL1

PL17 PL27

FS1

PL31

FS2 PL8

PL10 FS3 FS4 FS5

PL15 PL16 FS6

FS7

FS8

PL20

PL22 FS9

FS10

Figure 3.41 Motor PCB FHMB (1) layout view (fully-automatic)

L UXEL P LATESETTER VOLUME 2 (3-65)

FHMB (1) Main Device ICs

U27: U33: U39: U42: U43: TP1: TP2: TP3: TP5: TP6: TP7: TP8: TP9: TP13: TP16: TP17: TP18: TP20: TP22: TP23: TP24: TP30: TP31: TP32: TP33: TP34: Firmware. Electronic Programmable Logic Device. Controls and reads sensors. Electronic Programmable Logic Device. Solenoids and DC motors. Electronic Programmable Logic Device. Stepper motors. Electronic Programmable Logic Device. Controls and reads sensors. CAN Ground. Pulsed drive to opto-reflective sensors. CAN +5V. A-D Converter Ground. A-D Converter +5V. Vacuum sensor signal voltage. Digital Ground. System Reset. Out of Reset = virtually zero volts when measured from TP23. +24V Ground. Digital Ground. Pulsed drive to opto-reflective sensors. +5V supply to DC motor drivers. Digital Ground. Sensor Latch 2. Digital Ground. +5V Digital supply rail. Unprotected 5V. +24V. +24V Ground. +24V Ground. +24V Ground.

FHMB (1) Test Points

FHMB (1) Motor, Solenoid and Sensor Controls

Table 3.8 describes the devices connected directly to FHMB (1) or via a Distribution PCB. See also Figure 3.46 showing the Sensor Distribution PCB layout and Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the device connections for each variant, and Volume 2 Section 8.1 describing cable pin signals.

VOLUME 2 (3-66) P LATE H ANDLING M ODULES

Table 3.8 FHMB (1) device connections Device ID Motors: BM1 BM4 BM10 BM11 BM38 Friction and Band Input Punch Plate Centering Plate Pusher Output (Stepper-Man/Semi) 15 16 28 30 27 Device Description FHMB PL No Sensor Distribution (Input) PL No:

Solenoids and Relays: BV8 BV3 BV40 Sensors: BS1 BS2 BS8 BS9 BS80 BS113 BS114 BS115 BS116 BS118 Input Entrance Input Exit Punch Motor ON Position Punch Motor OFF Position Mixer Fan Detector Plate Centering Home Plate Centering Continuity 1 Plate Centering Continuity 2 Plate Pusher Home Plate on Platen 23 14 14 25 23 4 3 6 9 10 Error Warning Light (Alert) Mixer Fan SOL3 (Leading Edge) 1 1 10

3.4.1.2 FHMB PCB (4) Assembly

See Figure 3.42 showing the PCB layout describing the main FHMB functions.
NOTE: Connector boxes shown as shaded in the figure above have fitted connectors.

FHMB (4) Location

Mounted inside the Engine on the service side, top of the traverse beam (see Figure 3.40).

FHMB (4) LEDs and Links

There are no LEDs or links.

FHMB (4) Connectors

See Volume 2 Figure 9.3 to Volume 2 Figure 9.6 showing FHMB(4) cable interconnections and also Volume 2 Section 8.1 listing connections and signals.

L UXEL P LATESETTER VOLUME 2 (3-67)

PL1: PL2: PL3: PL4: PL5: PL6: PL7: PL8: PL9: PL10: PL11: PL12: PL13: PL14: PL15: PL16: PL17: PL18: PL19: PL20: PL21: PL22: PL23: PL24: PL25: PL26: PL27: PL28: PL29: PL30: PL31: SK1: SK2: SK3:

8-way male Molex header type STR 641. 2-way male Molex 6410 straight header. Not used. 4-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. To FPD. 6-way male Molex straight header. Not used. 8-way male Molex minifit Jr. PWR2 connection for STB (+24 V and +36 V). 4-way male AMP CT straight header. 3-way male AMP CT straight header. Not used. 8-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. Not used. 10-way male boxed header. Not used. 4-way male AMP CT straight header. 10-way male boxed header. Not used. 8-way male AMP CT straight header. Not used. 3-way male AMP CT straight header. 3-way male AMP CT straight header. 40-way male boxed header. Not used. 26-way male header. To RIB1 cable and Sensor Distribution PCB (Output). 26-way male straight header. To RIB2 cable to +24 V Distribution PCB 3-way male AMP CT straight header. Not used. 4-way male AMP CT straight shrouded header. To BS5 (Output Exit). 3-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 4-way male AMP CT straight header. Not used. 6-way male single in-line shrouded header top entry. 6-way male single in-line shrouded header side entry. Not used. 6-way male single in-line shrouded header top entry. 6-way male single in-line shrouded header top entry. 8-way Molex minifit Jr. PWR2 connection. 15-way female D-type. CAN5 from FHMB (3) for fully-automatic/ CAN_FHMB(1) for manual and semi-automatic. 45-way female R/A boxed header. Connects +36V DC, and CAN signals from FHMB(4) to the STB. 15-way female D-type. Not used.

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FHMB (4) Connector Pin Descriptions

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing FHMB(4) cable interconnections and also Volume 2 Section 8.1 listing cables and signals.
PL9 PL7 PL12 PL14 PL24 PL25 PL26 PL21 PL23 FS14

PL19 PL18

SK3

PL30

PL6 SK2 PL11

FS13

PL29 PL5

FS12

SK1

PL28 FS15

PL4

FS11

PL3 PL13 PL2 PL1

PL17 PL27

FS1

PL31

FS2 PL8

PL10 FS3 FS4 FS5

PL15 PL16 FS6

FS7

FS8

PL20

PL22 FS9

FS10

Figure 3.42 Motor PCB FHMB (4) layout view

FHMB (4) Fuses

FS1: FS2: FS3: FS4: 2A for Drum Vacuum motor. 2.5A. Not used. 2.5A. Spare. 2.5A. Not used.

L UXEL P LATESETTER VOLUME 2 (3-69)

FS5: FS6: FS7: FS8: FS9: FS10: FS11: FS12: FS13: FS14: FS15: U27: U33: U39: U42: U43: TP1: TP2: TP3: TP5: TP6: TP8: TP9: TP13: TP16: TP17: TP18: TP20: TP22: TP23: TP24: TP30: TP31: TP32: TP33:

2.5A for Friction and Band O/P motor. 4 A. Spare. 4A. Registration Pins motor. 2.5A. Not used. 2.5A. Spare. 2.5A. Not used. 2.5A. Centering. 2.5A. Not used. 2.5A. Push bar carriage. 2.5A. Bridge Feed to Processor. 2.5A. Spare. Firmware. Electronic Programmable Logic Device. Controls and reads sensors. Electronic Programmable Logic Device. Solenoids and DC motors. Electronic Programmable Logic Device. Stepper motors. Electronic Programmable Logic Device. Controls and reads sensors. CAN Ground. Pulsed drive to opto-reflective sensors. CAN +5V. A-D Converter Ground. A-D Converter +5V. Digital Ground. System Reset. Out of Reset = virtually zero volts when measured from TP23. +24V Ground. Digital Ground. Pulsed drive to opto-reflective sensors. +5V supply to DC motor drivers. Digital Ground. Sensor Latch 2. Digital Ground. +5V Digital supply rail. Unprotected 5V. +24V. +24V Ground. +24V Ground.

FHMB (4) Main Device ICs

FHMB (4) Test Points

VOLUME 2 (3-70) P LATE H ANDLING M ODULES

TP34:

+24V Ground.

FHMB (4) Motor, Solenoid and Sensor Control

Table 3.9 describes the devices connected directly to FHMB (1) or via a Distribution PCB. See also Figure 3.46 showing the Sensor Distribution PCB layout and Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the device connections for each variant.
Table 3.9 FHMB (4) devices connections Device ID Device Description FHMB (4) PL No: Sensor Dist (Output) PL No: 24 V Distribution PL No:

Motors: BM2 BM3 BM5 BM6 BM7 BM36 BM37 Solenoids: BV5 BV30 BV31 BV41 Sensors: BS3 BS4 BS5 BS6 BS10 BS11 BS12 BS13 BS14 BS15 Plate in Punch Output Entrance Output Exit Push Bar Home Registration Motor OUT Position Registration Motor IN Centering RH Detect Centering LH Detect Centering Home Position Push Bar Forward FWD Limit 7 12 2 8 6 9 10 11 7 2 Drum Vacuum Motor Control SOL 1 (Divert Valve) SOL 2 (Compressor Relay) SOL 4 (Blow and Air Knife) 1 10 8 16 Push Bar (Carriage) Centering (Punch) Registration Pins (Punch) Friction and Band Output Buffer Feed to Processor Reg Pin Mtr Continuity Swing Roller Motor 29 27 16 15 30 22 20 -

L UXEL P LATESETTER VOLUME 2 (3-71)

Table 3.9 FHMB (4) devices connections (Continued) Device ID Device Description FHMB (4) PL No: 4 25 9 9 12 23 Sensor Dist (Output) PL No: 4 3 24 V Distribution PL No: 6 4 1 -

BS19 BS20 BS21 BS79 BS100 BS103 BS104 BS109 BS110 BS112 BS118

Buffer Entrance Buffer Exit Fast Photo Detector Chad Tray Home Reg Pins Motor (Home) Reg Pin Motor (Out) Reg Pins Continuity Swing roller (Home) Swing roller (In) Push Bar FWD Plate on Platen (Opto)

3.4.1.3 Engine Distribution PCBs

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the PCB interconnections for each variant. A set of distribution PCBs are used to optimise machine cable runs between the Engine sensor devices and their handling FHMB. There are three Distribution PCBs on the Engine: Service side drum mounting plate PCBs:
A) B)

Registration Pin Isolation PCB (see Section 3.4.1.4) Sensor Distribution (Input) PCB Sensor Distribution (Output) PCB New 24V Distribution PCB

RFI Box mounting PCBs:

A) B)

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

PCB DRUM MOUNTING PLATE

REGISTRATION PIN ISOLATION

SENSOR DISTRIBUTION (INPUT)

Figure 3.43 Distribution PCBs - on drum mounting plate

Figure 3.44 shows two additional Distribution PCBs attached to the top righthand side of the RFI box.

RFI BOX (TOP)

SENSOR DISTRIBUTION (OUTPUT)

24V DISTRIBUTION

Figure 3.44 Distribution PCBs - top of RFI box

Sensor Distribution PCB (Output)

Figure 3.45 shows the layout of the Sensor Distribution PCB and Figure 3.40 shows its location on the Engine. The PCB supplies +5V to each of the sensors and returns signals to FHMB 4.

L UXEL P LATESETTER VOLUME 2 (3-73)

PL1 PL2 PL3 PL4 PL5

PL6

PL7

PL8

PL9

PL10

PL11

PL12

SET CAN ID 0

Figure 3.45 Sensor Distribution PCB (Output) - layout view

Sensor Distribution PCB (Input)

Figure 3.46 shows the layout of the Sensor Distribution PCB and Figure 3.40 shows its location on the Engine. The PCB supplies +5 V to each of the sensors and returns signals to FHMB 4.

PL5 PL4 PL3 PL2 PL8 PL7 PL6 PL11 PL10 PL9 PL12 SET CAN ID 0

PL1

Figure 3.46 Sensor Distribution PCB (Input) - layout view

24V Distribution PCB (New)

Figure 3.47 shows the layout of the New 24V Distribution PCB and Figure 3.40 shows its location on the Engine.

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PL8 PL5 PL3 PL7 PL10 PL12

PL11

PL2 PL1 PL4 PL6 PL9

Figure 3.47 New 24V Distribution PCB (FHMB 4) - layout view

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) B)

pin 2 = +24 V 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) B)

pin 2 = +5 V pin 3 = 0 V.

The 24 V Distribution PCB includes circuitry to attenuate the +24 V sensor signal to +5V before they are passed to the FHMB. See Volume 2 Section 9.4 showing system cable interconnections.

3.4.1.4 Registration Pin Isolation PCB

See Figure 3.48

Location
See Figure 3.40. Located on the drum mounting plate (service side) for all nonpunch platesetter variants.

Operation
A check for plate skewing occurs when the plate contacts both registration pins. Once electrical continuity is sensed between the two pins, the plate is deskewed.

L UXEL P LATESETTER VOLUME 2 (3-75)

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

Figure 3.48 Registration Pin Isolation PCB layout

NOTE: The registration pins must have clean oil-free surfaces to ensure electrical contact.

Connectors
PL1: PL2: PL3: 8-way header to registration pin 10-way header to FHMB (4). 4-way header to registration pin.

Connector Pin Descriptions

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7 showing the PCB interconnections 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)

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Location: centering mechanism beneath output module, see Figure 3.60. Type: stepper (Billows). Operation: drives centering arms IN and OUT. BM4 Punch Location: punch assembly - service side, see Figure 3.60. Type: DC (Billows). Operation: drives punch pins. BM5 Registration Pins Location: underneath Output module, see Figure 3.66. Type: DC (Billows). Operation: operates the registration pins on the punch. BM6 Friction Band Output Location: output module - service side, see Figure 3.57. Type: DC (66 rpm) with one-way clutch. Operation: drives plates from the drum to the Buffer. Note that this motor is replaced with a stepper motor (BM38) for Semi-Automatic machines. BM7 Buffer Feed to Processor Location: buffer module - Engine side, see Figure 3.69 Type: stepper Operation: drives plates from the Buffer to the Processor. BM10 Plate Centering Location: inside the plate loading platform, see Figure 3.55. Type: stepper Operation: centres the plate on the platen before loading. BM11 Plate Pusher Location: inside the plate loading platform, see Figure 3.55. Type: stepper Operation: pushes the plate towards the input module BM36 Registration Pin Location: operates the registration pins on the non-punch engine. Type: DC Operation: operates the registration pins. BM37 Swing Roller Motor Location: service side, inside the drum, see Figure 3.52. Type: 24 VDC with 60:1 gearbox Operation: operates roller in two directions to open and close spur wheels against the plate and improve leading edge conformance. BM38 Output (Stepper)

L UXEL P LATESETTER VOLUME 2 (3-77)

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.

3.4.1.6 Solenoids and Relays

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7. Solenoids and relays (BV) fitted on the Engine are listed as follows: BV3 Mixer Fan Location: underneath FHMB1 Type: 24 V Relay Operation: switches the mixer fan on/off during a scan in order to prevent thermal hot spots. BV5 Drum Vacuum Control Location: inside the interlock box, see Volume 2 Figure 6.7. Type: relay. Operation: controls the relay switching on 230 AC to the drum vacuum pump. BV8 Error Warning Light (Alert) Location: attached to the RFI box, underneath the interlock box. Type: relay Operation: external alert indication for the operator. When the machine ceases operation because the required media type is missing, the alert relay switches an external buzzer or flashing light. This alert is fitted by the customer as an option. BV30 BV31 BV40 BV41 SOL 1 (Divert Compressor) See Volume 2 Section 9.5 SOL 2 (Compressor Relay) See Volume 2 Section 9.4 SOL 3 (Leading Edge) See Volume 2 Section 9.5 SOL 4 (Blow and Air Knife) See Volume 2 Section 9.5

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

Operation: detects leading edge of plate in input nip. BS2 Input Exit Location: see Figure 3.56. Type: opto-reflective Operation: detects trailing edge of plate past push bar. BS3 Plate in Punch Location: see Figure 3.60. Type: opto-reflective Operation: detects leading edge of plate in punch. BS4 Output Entrance Location: see Figure 3.57. Type: opto-reflective Operation: detects plate in output. BS5 Output Exit Location: see Figure 3.57. Type: opto-reflective Operation: detects trailing edge of plate has left output. BS6 Push Bar Home Location: on a bracket where the bar is held in the Home position, service side, see Figure 3.52. Type: opto-slotted. Operation: detects when the push bar is at Home position (parked). BS8 Punch Motor Limits (On) Location: see Figure 3.61. Type: opto-slotted. Operation: punch motor is ON and pins are IN (extended). BS9 Punch Motor Limits (Off) Location: see Figure 3.61. Type: opto-slotted. Operation: punch motor is OFF and pins are OUT (retracted). BS10 Registration Motor Out Position Location: see Figure 3.60. Type: opto-slotted. Operation: registration motor pins are OUT (retracted). BS11 Registration Motor In Position Location: see Figure 3.60. Type: opto-slotted. Operation: registration motor pins are IN (extended).

L UXEL P LATESETTER VOLUME 2 (3-79)

BS14

Centering Home Position Location: see Figure 3.60. Type: opto-slotted. Operation: detects Home position.

BS15

Push Bar Forward Limit Location: mounted on drum casting below and left of punch motor at service end, see Figure 3.52. Punch Engine only. Type: opto-slotted. Operation: detects forward limit overrun.

BS19

Buffer Entrance Location: Buffer, engine side, see Figure 3.69 Type: opto-reflective Operation: leading edge indicates full buffer

BS20

Buffer Exit Location: Buffer, processor side, see Figure 3.69 Type: opto-reflective Operation: trailing edge indicates empty buffer.

BS21

Fast Photo Detect Location: drum casting, service side, see Volume 2 Figure 5.16. Type: photo-diode Operation: samples laser light power for spinner contamination and laser calibration.

BS79

Chad Tray Home Location: underneath the tray and accessed from underneath the optics base. Type: micro-switch Operation: indicates the presence of the tray.

BS80

Mixer Fan Detector Location: B_FAN cable pin link. Type: FHMB 1 interprets HIGH/LOW state if the B_FAN pin link has been inserted. Operation: detects if the fan cable has been re-connected after a service procedure.

BS100 Reg Pin Motor Home Location: Registration Module, see Figure 3.66. Type: opto-slotted Operation: indicates if the registration pins are retracted. BS103 Reg Pin Motor Out Location: Registration Module, see Figure 3.66.

VOLUME 2 (3-80) 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.

3.4.1.8 Mixer Fan

See Volume 2 Figure 9.5 to Volume 2 Figure 9.7. The fan is fixed to a bracket that swings free from the service side end cap opening and is switched on remove thermal hot spots during a scan. Leaving the supply cable disconnected after a service procedure will initiate an error code on power up. Sensor BS80 detects if the mixer fan lead cable has been reconnected after a service visit.

3.4.2 Engine Mechanical Modules

Figure 3.49 to Figure 3.54 show the main Engine assemblies used for conveying plates. See Volume 2 Section 4.1 for more information on the traverse assemblies. The main engine plate handling assemblies are: Plate Loading Platform - see Section 3.4.2.1. Input Module - see Section 3.4.2.2. Output Module - see Section 3.4.2.3. Drum - see Section 3.4.2.4. Transport Push Bar - see Section 3.4.2.5. Punch, Centerer and Registration Assemblies (Billows) - see Section 3.4.2.6. Swing Roller Module - see Section 3.4.2.10. Chad Tray (Punch Only) - see Section 3.4.2.11..

VOLUME 2 (3-82) P LATE H ANDLING M ODULES

FROM PLATE TRANSPORT TO PLATE OUTPUT OUTPUT MODULE FHMB4 INPUT MODULE FHMB1

BEAM PUNCH BS6 PUSH BAR CENTERING AND REGISTRATION MODULES

CHAD TUNNELS TO TRAY BS15 DRUM AND BASE PUNCH MOTOR

VACUUM SUPPLY FOR DRUM

Figure 3.49 Main engine assemblies (B1 fully-automatic with punch)

L UXEL P LATESETTER VOLUME 2 (3-83)

OUTPUT MODULE OUTPUT TRAY INPUT MODULE FROM PLATE LOADER

TO OUTPUT

BEAM

BS6 REGISTRATION MODULE PUSH BAR

SWING ROLLER MODULE

TRAVERSE GEARS FPD BS112

DRUM AND BASE

Figure 3.50 Main engine assemblies (B2 manual without punch)

VOLUME 2 (3-84) P LATE H ANDLING M ODULES

VALVE CAGE UMBILICAL TRAY BEAM

COMPRESSOR BOX

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 PUNCH MOTOR MIXER FAN TRAVERSE PCB PUSH BAR MOTOR

LIMIT SENSOR (BS15)

SERVICE END

Figure 3.52 Engine section view - service end (B1 fully-automatic with punch)

L UXEL P LATESETTER VOLUME 2 (3-85)

VALVE CAGE UMBILICAL TRAY BEAM

READHEAD

COMPRESSOR BOX

FLAT DRIVE RAIL V-RAIL FLYWHEEL MOTOR SWING ROLLER & REGISTRATION MODULE

BALL CAGE PUSH BAR

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 MOTOR

REGISTRATION 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

3.4.2.1 Plate Loading Platform

See Figure 3.56.

RACK SHORT BS113 LINEAR TRACK SHORT BS116 BM10

LH CENTRING ARM BS114 BS118 LINEAR TRACK LONG

RACK SHORT

RH CENTRING ARM

DRAG CHAIN LINEAR TRACK SHORT PLATE LIFT ROLLER BS115

RACK LONG

BM11 PLATE LIFT CARRIAGE

Figure 3.55 Loading platform view

The plate loading platform has two build versions: B1 Manual and Semi-Automatic

L UXEL P LATESETTER VOLUME 2 (3-87)

B2 Manual and Semi-Automatic. Both platforms have similar design and assemblies except for the differences in size for handling B1 and B2 plates. The loading plateform consists of: Racks (long and short) and a pinion for centering Centering arms Rack for driving the plate pusher motor. Sensors and motors: see Figure 3.55.

3.4.2.2 Input Module

This module has three different build versions for: B1 Automatic B2 Manual and Semi-Automatic B1 Manual and Semi-Automatic. Figure 3.56 shows the B1 Fully-Automatic input module. For servicing puposes, all three builds are similar. An air knife/curtain provides a stream of compressed air across the plate before it passes into the drum. Contaminants on the plate are removed before they enter the drum. A description of plate contamination control is in Volume 2 Section 7.3. Air is supplied from the compressor box with the flow controlled from the solenoid (BV41) located on the valve cage.

VOLUME 2 (3-88) P LATE H ANDLING M ODULES

NOTE: AIR KNIFE FITTED ON PTM FOR FULLY AUTO MACHINES SENSOR BS1 ROLLER (IDLE) BEARING FROM PTM

AIR KNIFE

MOTOR BM1

INPUT BELT

DUCTING PIPE BV41

ROLLER (FRICTION) ROLLER (IDLE) SENSOR BS2

TO DRUM SIDE PLATE ROLLER (DRIVEN) MANUAL PLATE FORWARD

VIEW ON ARROW A

GEAR VALVE CAGE (SEE CHAPTER 2-7)

GEAR PULLEY

TENSIONER

Figure 3.56 Input module - general view (B1 fully-automatic)

3.4.2.3 Output Module

See Figure 3.57 and Figure 3.58. This module uses a common assembly with different output guides for the main variants shown in Table 3.10. The module consists of:

L UXEL P LATESETTER VOLUME 2 (3-89)

Sensors: BS4 and BS5. Motor: for more precise control in moving a plate, a stepper output motor (BM28) is fitted on the Manual and Semi-Automatic machines instead of a DC motor (BM6). Output Guide: there are different versions of the guide, depending on the variant. See Table 3.10. Rollers and belts: the rollers are held to the side plate by removable bearings. These can be removed in-situ.
Table 3.10 Output guide plates and variants
Variant Output plate description

B1 fully-automatic B1 semi-automatic B1 manual B2 semi-automatic B2 manual

Output guide with Buffer module Output guide with Buffer module Output guide with output tray Output guide with driven output tray (buffer) Output guide with output tray

SPUR GEAR (76T)

CROWN ROLLER OUTPUT BELT OUTPUT FRICTION BELT

OUTPUT PLATE LH

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

Figure 3.58 Variant output module guides - detail view

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:

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.

4 4

Slow: traverse direction Fast: spinner rotation direction.

L UXEL P LATESETTER VOLUME 2 (3-91)

NOTE: Follow the drum cleaning procedure in Volume 3 Section 1.5.4.

3.4.2.5 Transport Push Bar (Spring)

See Figure 3.59. The spring bar (Mark 2), fitted to all Violet variants, is a modified version of the Green push bar. It includes the following features: Spring shoes replaces the mounted blade for plate contact (note that these are replaced every 12 months). The distance between springs depends on the maximum size of plates used on the machine. Clutch is not fitted. The complete assembly easily removed and installed. The bar is designed as an accurately aligned assembly biased to the drum surface to ensure the plate is not skewed against the registration pins and is conformed to the drum for accurate registration. The bar moves around the drum using a drive shaft with two pinions either end that locate on gear segment rings. The strip contacts the trailing edge of the plate and drives it until the leading edge reaches the registration pins on the punch assembly. Sensors: BS15 (fully-automatic) detects the forward limit of travel towards the punch and BS6 indicates the bar Home position. Motor: motor (BM2) and gearbox drives the assembly using adjustable gear segments set into the drum. Service checks need to be made on the push bar for:
A)

Mechanical conformance: note that the plate can be poorly conformed mechanically and still have adequate vacuum conformance. Spring shoes: these may need to be replaced annually, depending on production rate. Pitch ring: these are checked during each visit for Delrin flakes, see Volume 3 Section 1.6.3.

B)

C)

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 different 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

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specification. Fully-Automatic Machines Only: plate skew is sometimes caused by poor alignment 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 correctly conformed to the registration pins, see Volume 3 Section 1.8.3.
SPRING SHOE

WHEEL ASSEMBLY DRIVE SHAFT

SPUR GEAR PITCH RING ASSEMBLY ROLLER PLATE NIP ROLLER ROLLER PLATE MOTOR END PLATE SUPPORT BAR HOME SENSOR (ON DRUM) BLANKING BRACKET

DRIVE SHAFT

HUB SPUR GEAR PITCH RING V3 ASSEMBLY PITCH RING BEARING STUB SHAFT GEAR MOTOR MOTOR MOUNTING BRACKET

Figure 3.59 Transport push bar (Mark 2) general view

Note that typical NVRAM parameters for the Mark 2 are different to the Mark 1:
A) B) C)

PUSH_BAR_CENTER_DIST_LONG_MM = 11 PUSH_BAR_CONF_DIST_THIN__MM=6 CENTERER_RELEASE_DIST_MM=1.0.

L UXEL P LATESETTER VOLUME 2 (3-93)

3.4.2.6 Punch, Registration and Centerer (New Billows)

The complete punch, registration and centering assembly is fitted on the B1 platesetter as a Billows (New) version with minor changes on the centering mechanism and registration pivot from the Old version: The New version has the following sub-assemblies: Registration: a pin mechanism to stop the leading edge of a plate in a reference position for imaging. Centerer: a finger mechanism to centre the plate prior to punching. Punch: a pin, die and guide mechanism with a plate punch configuration suited to the customers production needs. Sub-assemblies are replaced and adjusted by either removing the complete assembly (see Volume 3 Section 2.4.7.1) from the machine or by accessing the required part without removing the assembly.

BS14 CENTERER MOTOR (BM3)

REGISTRATION PIN MOTOR (BM5)

CENTERING ARM (LH) BS3

A
LOCKNUT BS10 REG PIN CAM PIVOT UNDERNEATH VIEW ON ARROW A CRANK ARM MOTOR SUPPORT BRACKET PUNCH MOTOR (BM4)

SPRING

BS11

ACTUATING ROD

Figure 3.60 Centerer and registration assemblies (New Billows)

VOLUME 2 (3-94) P LATE H ANDLING M ODULES

Using Punch Diagnostic Commands

From the diagnostic service menu you can operate the punch, centerer and registration motor/sensors using the following commands: punch mechanism:
service/actuators> set bm4 <on/off/dis/no>

registration mechanism:
service/actuators> set bm5 <on/off/dis/no>

centerer mechanism:
service/st_motors> setmotors centerer service/st_motors> move 2000 800

Punch Mechanism Assembly

See Figure 3.61 and Figure 3.62.
VIEW ON SERVICE END OF PUNCH ASSEMBLY ACTUATING ARM

VANE EXTENSION TAB

BS9 BS8 MOTOR SUPPORT PLATE

A
PUNCH MOTOR

A = RETRACT B = EXTEND

Figure 3.61 Punch sensors - location view

The punch sub-assembly comprises: Punch pins, dies and guides. Cam, lever arm and shoulder screw (with washers). Actuating lever, punch shaft and linkages. Motor (BM4) and gear head. Punch motor limit sensors (BS8/9) and plate in punch sensor (BS3).

L UXEL P LATESETTER VOLUME 2 (3-95)

A punch assembly (with integral pins and dies) is supplied as one of the configurations 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.

PUNCH ACTUATOR BAR ACTUATING LEVER

CAM SHOULDER SCREW VIEW FROM USER SIDE

MOTOR DIRECTION

DRUM FACE

Figure 3.62 Punch lever assemblies

Punch Mechanism Operation

Figure 3.62. Attached to the assembly is a motor bracket that includes a cam for rotating the pin actuator lever arm (via a shoulder screw) and punch shaft. Two limit sensors indicate the following: BS8: pins are extended (in punch). BS9: pins are retracted (out of punch). Sensor BS3 detects the leading edge of a plate to indicate that the media has entered the punch successfully.

Registration Mechanism Assembly

See Figure 3.60. The registration mechanism comprises:

VOLUME 2 (3-96) P LATE H ANDLING M ODULES

Registration pin motor (BM5) and gear head. Pin cam (eccentric) attached to the motor arm. Actuating rod that mechanically drives the pin bar. Sensors BS10/11 indicate to the system if the pins are extended or retracted. Registration pins (6-off) attached to bar.

Registration Mechanism Operation

When driven by BM5, the pins have two possible positions:
1. 2.

Extended: the pins are in the plate path and the plate leading edge is stopped. Retracted: the pins are out of the plate path and the plate can be pushed towards the Buffer.

Centerer Mechanism Assembly

See Figure 3.60. The plate centering mechanism comprises: Two centerer arms (fingers) and rails driven by motor (BM3) via a rack and pinion. Centerer motor (BM3) and gear head Centerer home sensor (BS14) allowing the arms to be set at 1174 mm apart. Centering is achieved when there is electrical continuity between the two side fingers and the plate.

Centerer Mechanism Operation

The plate is aligned for punching by the centerer after it is pushed into the punch assembly. A centering operation occurs as follows:

1. Extended registration pins stops the plate leading edge in a datum position. 2. Centerer fingers in the Home position move inwards until both the left and
righhand side detect a plate, indicating the plate has been centered. not reached the punch or if step 2. above fails.

3. The fingers attempt to centre the plate and issue an error code if the plate has 4. The fingers move back towards Home before the plate is conformed.

3.4.2.7 Punch Configurations

Customers can fit a range of configurations for a punch based on the configurations described in Table 3.11 and illustrated in Figure 3.63.

L UXEL P LATESETTER VOLUME 2 (3-97)

HEIDELBERG+BACHER

780 mm 748 mm 425 mm 11 mm A B 8 mm MAN ROLAND / MATSUMOTO / HEIDELBERG B A 393 mm A C A C A = BACHER B = HEIDELBERG C = HEIDELBERG PUNCH A 6.35 mm x 9.525 PUNCH B 12.68 mm x 10 PUNCH C 12 mm x 14.68 mm

780 mm

425 mm 11 mm PUNCH A 12.68 mm x 10 PUNCH B 12 mm x 12 mm

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 PUNCH B 6 mm x A A B B

10 8

Figure 3.63 Plate punch configurations

VOLUME 2 (3-98) P LATE H ANDLING M ODULES

Table 3.11 Plate punch configurations and part numbers

Punch Type Punch Assembly Part No

Dummy Heidelberg+Bacher Man Roland/Matsumoto/Heidelberg Komori Custom

7A03595 7A03596 7A03597 7A03598 7A03600

3.4.2.8 Punch, Registration and Centerer (Fuji)

This punch (referred to as Fuji) is an advanced design on the Billows punch. It uses similar ID numbering for motors and sensors, and includes the registration, centerer and punch modules that operate in a similar way to the Billows punch. New features for the Violet punch include: Fabricated in aluminium as a complete casting. Uses Beryillium copper wiper strips to prevent chad collecting inside the die. Accessible sensors and motors for improved servicing. Facility to extend the service life of the punch crop pins.

S10

CENTERING MOTOR (BM3) REG PIN DC MOTOR

S14 CENTERING ARM (RH)

CENTERING ARM (LH)

S13 S12 PIN/DIE/ CHAD WIPER BS3

A
PUNCH MOTOR (BM4) BS8/9

CENTERING MOTOR S11

REG PIN CAM

NOTE: S12/S13 FITTED TO CENTERING FINGERS ON HIDDEN SIDE REG PIN ACTUATING ARM

REG PIN DC MOTOR (BM5)

UNDERNEATH VIEW ON ARROW A

CENTERING PINION

ACTUATING SHAFT

Figure 3.64 Punch, registration and centerer (Fuji)

L UXEL P LATESETTER VOLUME 2 (3-99)

3.4.2.9 Registration Module

See Figure 3.65 and Figure 3.66. Fitted at the output end of the drum casting and accessible from the rear of the Engine on all variants except for the fully-automatic (with punch). The module operates two registration pins that stop the leading edge of a plate before vacuuming and imaging. Electrical continuity between the two pins and the plate indicates that the plate is not skewed. Once factory fitted, the registration module is never removed from an on-site machine.
SIDE PLATE

PLATE GUIDE

REGISTRATION MODULE

DRUM CASTING

BACK STAY

Figure 3.65 Registration module (drum view)

VOLUME 2 (3-100) PLATE H ANDLING M ODULES

MOTOR BRACKET

SENSOR

ACTUATING SHAFT BEARING BLOCK

SENSOR

GEARMOTOR

BASEPLATE

Figure 3.66 Registration module (detail view)

3.4.2.10 Swing Roller Module

See Figure 3.67. This module is installed on all variants except for the fully-automatic (with punch) system. The swing roller module is fitted on the drum output and serves to:

The roller assembly consists of: DC motor: 24 VDC with 60:1 gearbox with spur gear Nip wheels: rubber wheels Sensors: BS109 and BS110 to indicate if the nip wheels are in the Home position (OUT) or IN

4 4

conform the leading edge of the plate to the drum for imaging guide the plate leading edge at the eject stage towards the output module.

L UXEL P LATESETTER VOLUME 2 (3-101)

SENSOR (BS110)

SIDE PLATE BACK BACK STAY

SIDE PLATE FRONT

MOTOR MOTOR BRACKET SENSOR (BS109)

PLATE GUIDE

SHAFT

NIP WHEELS

Figure 3.67 Swing roller module (detail view)

3.4.2.11 Chad Tray (Punch Only)

See Figure 3.68 and Figure 3.49. A chad tray for the punch waste material is emptied by the operator at periods determined by a software count. See the Luxel Platesetter Operator's Manual for an illustration of the warning icon on the MMI. As a service procedure, make sure that the chad exits correctly from all the punch pin channels. A micro-switch (BS79), located at the far end of the tray, detects if the tray is in the Home position. Access is from underneath the optics base after the rear panel has been removed.

VOLUME 2 (3-102) PLATE H ANDLING M ODULES

CHAD TRAY

PULL

Figure 3.68 Locating the chad tray

3.5 Buffer Plate Handling Modules

The Buffer consists of: Control assemblies - see Section 3.5.1 Mechanical assemblies - see Section 3.5.2.

3.5.1 Buffer Control Assemblies

See Figure 3.69 showing the interconnection and locations of the control assemblies. B1/B2 fully-automatic and semi-automatic platesetters: these are fitted with a bridge conveyer to ensure a regulated flow of plates between the engine and the processor. B2 semi-automatic platesetters: these have a guide plate from the engine and a box cover to bridge the two units.

3.5.1.1 Buffer Control Modules

See also Volume 2 Section 2.2.1. Motor/gearbox Sensors.1. A band roller assembly on the Buffer moves the drive belts to synchronise

L UXEL P LATESETTER VOLUME 2 (3-103)

scanned plate outputs from the Engine with the transport rollers in the Processor. 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

MOTOR AND GEAR ASSEMBLIES

STEPPER MOTOR

GUIDE GEAR DOUBLE SPUR GEAR SENSOR (BS20)

SENSOR (BS19)

SERVICE SIDE SIDE PLATE PLATE RAMP ADJUSTER RAIL DRIVE BELT BEARING/RETAINER CLIP SENSOR BRACKET

BAND ROLLER

Figure 3.69 Buffer assemblies (old)

VOLUME 2 (3-104) PLATE H ANDLING M ODULES

BS19:

Buffer Entrance: Location: see Figure 3.69. Type: Opto-reflective. Operation: detects the presence of a plate at the Buffer entrance after the output module.

BS20

Buffer Exit Location: see Figure 3.69. Type: Opto-reflective. Operation: detects the presence of a plate at the Buffer exit before the Processor.

3.5.2 Buffer Assemblies (New)

The New Buffer operates as transport bridge between the Engine and the Processor using drive belts, gears and rollers. It is similar in operation to the old Buffer except: New Buffers are not fitted with a labyrinth or height adjuster. New Buffers include a removable top cover to access motors and sensors.
IDLER GEAR

MOTOR AND GEAR ASSEMBLIES

STEPPER MOTOR

GEAR DOUBLE SPUR GEAR

GUIDE

SENSOR (BS20) SENSOR (BS19)

BAND ROLLER SERVICE SIDE SIDE PLATE DRIVE BELT PLATE RAMP ADJUSTER RAIL BEARING/RETAINER CLIP SENSOR BRACKET

Figure 3.70 Buffer assemblies (new)

L UXEL P LATESETTER VOLUME 2 (3-105)

3.6 Inter-Module Connections and Control

3.6.0.1 Autofeeder-to-PTM Interconnections
Control and power interconnections from the Autofeeder are routed from the PTM using the arrangement shown in Figure 3.71.
SCREW FIXING (SEE NOTE) REMOVE SERVICE SIDE COVER ELV_IN ELV_LOCK RIB8

VIEW FROM SERVICE SIDE

CONNECTOR I/F PLATE PA MAINS_ELV_IN SCREW FIXING (SEE NOTE) NOTE: REPEAT SCREW FIXING POINTS ON USER SIDE AUTOFEEDER INTERIOR FRAME CONNECTIONS

Figure 3.71 Autofeeder-PTM control interconnection

NOTE: The Autofeeder must be mechanically coupled with the PTM so that there is no risk of light `fogging' plates.

3.6.0.2 PTM-to-Engine Interconnections

Control and power from the Engine to the PTM use the connector interface shown in Figure 3.72. Note that the PTM must be mechanically coupled with the Engine and Autofeeder so that there is no risk of plate `fogging'.

VOLUME 2 (3-106) PLATE H ANDLING M ODULES

REMOVE SERVICE SIDE COVER

SCREW FIXING (SEE NOTE)

CAN3_INT (CAN B)

CAN5_INT (CAN A) CONNECTOR I/F PLATE EP

FHMB3

PWR3_INT (8W)

INT_EMERG (6W)

FEED_INT (10W)

VACUUM INLET INT_MAINS RELAY

SCREW FIXING (SEE NOTE)

PTM INTERIOR FRAME CONNECTIONS

NOTE: SCREW FIXING POINTS ON EACH SIDE

Figure 3.72 PTM-Engine control interconnection

3.6.0.3 Buffer-to-Engine Interconnections

Control and power interconnections from the Engine are routed to the Buffer using the drive arrangement shown in Figure 3.73. Note that the Buffer must be mechanically coupled with the Engine so that there is no risk of light fogging plates. A fume flap between the Buffer and Engine prevents chemical contamination inside the Engine.

L UXEL P LATESETTER VOLUME 2 (3-107)

SERVICE SIDE BUFF_S19/20

BUFF_M7

INTERLOCKS

BUFFER ENTRY ON ENGINE

CONNECTOR I/F EB

Figure 3.73 Buffer-Engine interconnections (old)

SERVICE SIDE

CONNECTOR I/F EB BUFFER ENTRY ON ENGINE

INTERLOCKS

BUFF_M7

BUFF_S19/20

Figure 3.74 Buffer-Engine interconnections (new)

VOLUME 2 (3-108) PLATE H ANDLING M ODULES

Volume-Chapt er

TRAVERSE SCAN MODULES

This chapter describes the main traverse modules and how the scan system operates:

4.1 Introducing the Traverse Scan Modules

See Volume 1 Section 2.3 introducing the traverse scan system and Volume 3 Section 3.1 describing how traverse scan FRUs are replaced. The media scan system includes the modules shown in Figure 4.1. with their physical location shown in Figure 4.2.
NOTE: All Luxel platesetter variants use the same traverse scan modules and method of operation.

4.1.1 Beam Assemblies

A cast aluminium beam provides the main support for the traverse carriage and includes the following sub-assemblies: V-groove rail: provides a sliding surface for the ball cage. Ball cage: a precision assembly of ball bearings that allow the carriage to slide along the V-groove. Both carriage and cage need to be physically aligned using the procedure in Volume 3 Section 1.7.2. A separate software utility checks for `creep' (ie the two assemblies gradually become misaligned as the system constantly traverses) Drive rail: provides a drive rail for the traverse motor spindle and a base for the linear scale. Linear scale: runs along the drive rail to provide position coding for the readhead encoder. Actuators: All position measurements are offset from two actuators that indicate the exact reference (Index) and coarse reference (Home).

4 4 4

Introducing the Traverse Scan Modules .................................................................. 4-1 Media Scan System Description ............................................................................... 4-7 Edge Detect System Description ............................................................................ 4-18

2-4-2 T RAVERSE S CAN M ODULES

4.1.2 Traverse Carriage Assemblies

The carriage assembly is motor-driven to run along the beam drive rail from its Home position on the Service side. Scanning is from the user to the service end. A traverse motor, which moves the carriage, is controlled directly from the Traverse PCB that operates as a CAN node. Position feedback is provided by a readhead sensing micro positions on the linear scale; commands from the System PCB, via the Traverse PCB, control the position and direction of the carriage. Traverse PCB: this PCB runs local software handling routines for operating the traverse carriage mechanisms. See also Section 4.1.2.1. Spinner: the spinner (Speedring type) includes an encoder that returns an Index signal for each revolution and a rotating mirror for reflecting the laser beams onto the plate. See Section 4.2.2. Baffles: two baffles are fitted: removable and fixed. Baffles are fitted to help conform film to the drum and prevent laser light scattering on the plate. See Section 4.2.1.1. Traverse Motor: a DC motor drives a spindle along the drive rail. Readhead: an encoder with sensors that reads the micro positions on the linear rail to detect current position. Umbilical: an umbilical ribbon cable from the Traverse PCB to FHMB4 connects the CAN control/status signals and the power voltages. The cable is positioned along a tray and flexes as the carriage traverses the drum. Edge Detect PCB and Laser: detects the side edge of the plate for calculating a horizontal start imaging position. See Section 4.3. The carriage is removed from the engine using two extenders fitted to the beam. Most service procedures are completed while the carriage is located on the extenders.

BEAM

LSB

READHEAD ACTUATORS

SCALE

CAN

FLYWHEEL/ MOTOR/ SHAFT

POSITION DATA

DRIVE RAIL

FROM OPTICS BASE LASER BEAM +36V SPINNER INDEX

DC DRIVE TRAVERSE PCB UMBILICAL (CAN + POWER) EDGE DETECT LASER/PCB

ENCODER MIXER FAN (OUTSIDE END CAP) BAFFLE (SERVICE END)

Figure 4.1 Media scan system assemblies

FHMB (4)

L UXEL P LATESETTER 2-4-3

PCB SUPPORT BRACKET READHEAD PCB BAFFLE SPINNER READHEAD SUPPORT BRACKET

V-GROOVE RAIL

2-4-4 T RAVERSE S CAN M ODULES

TRAVERSE CARRIAGE WIPER

BAFFLE BRACKET (FRONT)

L6 LENS ASSEMBLY SPINNER CLAMP

EDGE DETECT PCB AND LASER

MOTOR SUPPORT

MOTOR FLYWHEEL CLAMP

Figure 4.2 Traverse assemblies - general view

BAFFLE BRACKET (REAR) TRAVERSE PCB BEARINGS BEARING PLATE MOTOR SHAFT

FLYWHEEL

REMOVABLE BRACKET

L UXEL P LATESETTER 2-4-5

4.1.2.1 Traverse PCB

See Figure 4.2 and Figure 4.3.

PL11

PL12

PROCESSOR TP26

PL9

PL10

TP10 TP9

PL6

PL7

PL1 PL2

PL4

PL5

Figure 4.3 Traverse PCB layout

Location
Located on the PCB support bracket on the underside of the carriage, see Figure 4.2.

LEDs and Links

There are no LEDs or links.

Traverse PCB Connectors

A)

PL1: Molex mini-fit 4-pin to Traverse motor.

2-4-6 T RAVERSE S CAN M ODULES

B) C) D) E) F) G) H) I) J)

PL2: Molex milligrid 16-pin header to Traverse Encoder (readhead). PL3: Not used. PL4: Molex mini-fit 8-pin to Spinner encoder. PL5: Molex mini-fit 12-pin to Spinner motor. PL6: Not used. PL7: Not used. PL8: Not used. PL9: Not used. PL10: 45-way connector for umbilical flexible cable (power, spinner signals and CAN bus). PL11: Not used. PL12: Not used.

K) L)

Connector Pin Descriptions

See Volume 2 Section 8.1.

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. 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. TP26: DATA A signal (960 lines/rev).

B)

C)

4.1.2.2 Traverse PCB Functional Description

The Traverse PCB controls the spinner and traverse mechanisms, and also provides the drive currents for the spinner and traverse motors.

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 closedloop 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

4.2 Media Scan System Description

4.2.1 Scanning Overview
This section describes the function and operation of the scan system control modules that operate around the Traverse PCB. The media scan control system is broadly divided into two areas: Spinner control: a high-speed air-bearing spinner driven by a brushless dc motor. The spinner includes a mirror to reflect laser beams onto the plate and an enclosed rotary encoder that supplies a SPIN INDEX signal to the System PCB. Traverse control: a spinner carriage mounted on beam that runs the length of the drum. Position feedback is taken from a readhead and a linear scale fixed to the drive rail. Spinner and traverse operations are managed locally by a Traverse PCB attached to the carriage. Carriage motion is from a friction drive shaft turned by a dc motor. Note that the shaft has a precise diameter and any dirt or damage on or around the shaft will give a mis-registration pattern. The scanning system controls the traverse mechanisms and consists of the following features: dedicated precision motion controller traverse closed-loop servo compensation system traverse motor amplifier two sensors to detect positions from fixed actuators on the drive rail: coarse Home position exact Index position (reference)

linear encoder supplying position data. Expose scanning to plate is from a spinner that has the following features: discrete Traverse PCB circuitry that controls the drive current spinner feedback encoder signals to regulate speed and avoid fluctuations 3-phase supply with transistor switching to energise the motor windings braking from an System PCB command. The traverse carriage is supported on a linear bearing and a plain drive rail, see Figure 4.6. Both bearing and drive rail are parallel to a beam which runs the length of the drum. The linear bearing consists of a long V-groove section fixed to the beam, and a short section mounted on the carriage. An open ball cage assembly separates the two sections. A traverse motor shaft, supports and drives the carriage along a plain drive rail that holds the linear scale and the traverse reference actuators. The ball cage and traverse rail are aligned to ensure that the cage is always under the rail for the entire travel of the carriage. Volume 3 Section 1.7.1 describes the alignment procedure.

4 4

2-4-8 T RAVERSE S CAN M ODULES

4.2.1.1 Mixer Fan and Baffles

A mixer fan mixes (equalises) the drum air thermals around the spinner to prevent error patterning. The fan is mounted on a hinged bracket that locates outside the drum end cap on the service side and is controlled from a relay fitted on the engine underneath FHMB1. Two baffle assemblies are fitted on the carriage to prevent light scattering from the plate surface and exposing other areas of plate. The baffle (user side) is removable for spinner mirror cleaning; the baffle (service side) is fixed.

4.2.1.2 Traverse PCB Imaging Control

When the system is ready to output an image, the Traverse PCB receives information from the System PCB on:
1. 2. 3. 4. 5.

horizontal start of image (right-hand edge when the machine is viewed from the front) vertical start of image (first part of image exposed after the Index pulse) image resolution number of laser beams (1 or 2) traverse direction of imaging (user to service end).

The Traverse PCB then moves the carriage to the correct position. After image data has finished downloading from the RIP, the System PCB instructs the Traverse PCB to start scanning.

4.2.1.3 Scan Interlock Protection

The covers and doors on the platesetter are interlocked using the system fully described in Volume 1 Section 3.3. If a cover is opened, and the interlocks not overridden, voltage supply (+36V and +24 V) to the Traverse PCB is removed. This halts spinner rotation.

4.2.1.4 Traverse Diagnostics

Traverse PCB on-board diagnostics check for cage creep if the engine traverse level falls outside the specification. A set of utilities allow you, for instance, to move the carriage to a set position, to datum the carriage or halt the traverse.

4.2.1.5 Umbilical Interface

Electrical and power connection to the scanning system is from a 45-way flexible ribbon cable. This conveys power and CAN command signals to the Traverse PCB, and returns status signals to the System PCB. With the exception of the CAN bus, all other differential signals are RS422 interface standard.

4.2.2 Spinner Control Subsystem

Spinner control is a closed-loop system with a common clock source to the spinner control circuit and traverse controller. All the main spinner control functions are located on the Traverse PCB. Commands for the spinner (for instance, Start/ Stop and Full/Idle Speed) are transmitted to the controller via the CAN bus from the System PCB.

L UXEL P LATESETTER 2-4-9

4.2.2.1 Spinner Encoder

The spinner is fitted with a rotary encoder that provides two differential signals: DATA A with a resolution of 720 lines/rev. This signal is used locally for the spinner closed-loop control, and is transmitted back to the System PCB where it is multiplied for use by the pixel data clock. It is compared (on the Traverse PCB) to a crystal-derived reference clock to give an error signal, via a compensation circuit, that varies the current to the spinner motor windings. SPIN INDEX occurs once per spinner revolution. This signal is transmitted directly to the System PCB where it is used to synchronise the carriage and spinner mirror positions.

4.2.2.2 Spinner Controller

This function operates from the Traverse PCB and is responsible for driving the spinner motor based on feedback information derived from the encoder. The controller regulates motor current by varying the duty cycle of the switching waveforms applied to the power stage. At 40,000 rpm, the pulse width modulation signal and the Hall effect signals are synchronised. Also, the traverse and spinner speeds are synchronised from the same reference clock signal to ensure correctly aligned raster imaging. See Section 4.2.4 below.

4.2.2.3 Spinner Diagnostics

A set of service diagnostics for the spinner is available to start and stop the spinner, display index counts, set image offset position on the plate and run spinner auto-tests..

4.2.2.4 Spinner Condition Sensing and Braking

Besides the servo loop, spinner control is also determined by a number of external conditions and detector signals that are monitored for diagnostic use.

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) B)

the spinner controller initialises power is removed from the Traverse PCB (for instance, an interlock is opened) on-demand signals via the software.

C)

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

Hall Effect Sensor Failure

The controller monitors the validity of the Hall effect sensor codes when the spinner starts to turn. There are six valid (and two invalid) codes depending on the initial rotor positions. On detection of an invalid code, power is removed from the motor.

Overspeed/Underspeed Detection
Power is removed from the motor if the spinner is stalled or is rotating too slowly. Speed is calculated from the spinner shaft encoder.

Over-temperature
Local ambient temperature around the spinner output terminals on the Traverse PCB is monitored by an on-board detecting device. If the temperature exceeds 100C, the controller removes power to the motor.

4.2.3 Traverse Motor Control Subsystem

See Figure 4.4. Direction of traverse travel can be both ways depending on system software decisions, although normal scanning direction for imaging is from user to service end. Datum is determined from two sensors in the readhead which are actuated by two magnets: Home (HOME) - coarse detection Index (TRAV INDEX) - fine reference detection.

Units of measurement on the traverse system are in microns with the Index actuator defined as position 0. The valid range of the beam (in microns) is approximately 0 m to -1,220,000 m in steps of 1 m.
DRUM 1,220,000 m VE +VE

4.2.3.1 Linear Encoding

Position and servo control for the traverse is derived from signals fed to the Precision Motion controller by a readhead digital encoder system (Renishaw RGH22).

4 4

CARRIAGE RAIL

HOME INDEX ACTUATOR

SE EN

Figure 4.4 Traverse positioning

L UXEL P LATESETTER 2-4-11

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 Support.

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 supply 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 scatter light towards the readhead window. An index grating inside the device redirects 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 produce 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 OBLIQUE LIGHT FROM INFRA-RED LED

READHEAD WINDOW

CLEARANCE 0.8 mm CONTAMINANTS COATING GOLD PLATED SCALE FACETS PITCH 20 M

SCALE SCATTERS LIGHT > 100 ACTIVE FACETS RAIL

Figure 4.5 Readhead operation

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.
NOTE: A correctly setup readhead is essential for accurate encoding.

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 carriage 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 proportional to the input. Output current from the amplifier is fed back to an MPU A-to-D channel for diagnostic measurement.

Traverse Motor Assemblies

This is fitted to the carriage casting as an assembly of: Motor: a brush DC motor (with casting). Motor shaft: a friction shaft that consists of a hardened silver steel with a central crown that moves along the drive rail. Avoid damaging or knocking this item. The diameter of the shaft is 9 mm. Flywheel: used to smooth the speed of the carriage along the rail. Turn the flywheel by hand to start the traverse along the rail. Drive rail wiper: forms a housing over the motor shaft and includes an arrangement of felt pads that keeps the motor shaft clean as the carriage moves. Both the rail and shaft must be free of contaminants to avoid misregistration.

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

Figure 4.6 Location of actuators and linear scale

Carriage Position Encoder

This consists of a linear scale fixed to the drive rail, and a readhead attached to the carriage which passes over the scale as the carriage moves. Position data is passed directly to the Traverse PCB for use by the servo control. Resolution for position movement is set at 1 m. The readhead also includes two sensing circuits (Index and Home) triggered by

L UXEL P LATESETTER 2-4-15

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.
COARSE HOME POSITION SIGNAL CARRIAGE TRAVEL ACCURATE INDEX SIGNAL RAIL CARRIAGE STOP

Figure 4.7 Home and Index signal relationship

Index Actuator (Reference Mark)

This sensor actuator is positioned opposite the Home actuator and provides a precise reference point for linear movement. All absolute positions are measured from the point where the TRAV INDEX signal is asserted. The index signal (TRAV INDEX) is active for the same distance as the main scale (1 m). It is repeatable, short and accurate, and is asserted approximately 5 mm 'inside' the Home sensor region. This sensor is always approached by the carriage from the same direction during the datum operation to ensure the highest repeatability. The method is as follows:
A) B) C)

a valid Home signal is detected carriage moves left slightly beyond the Index sensor moves right and halts on the left-hand edge of the Index sensor.

Because the position of the reference mark pulse is set for very high precision repeatability, some form of registration is necessary. Using the readhead LED indicators, the optimum phasing of the reference mark trigger signal, relative to the incremental signal from the scale, is determined. A screw fixing on the actuator sets the correct registration. If the readhead mounting is disturbed, or the readhead is replaced, the reference mark will need to be re-registered using the procedure supplied by the manufacturer's Installation Guide. Make sure the retaining screws for the readhead are not disturbed.

2-4-16 T RAVERSE S CAN M ODULES

Overspeed and Braking

To prevent traverse control from driving the carriage too fast, the rate of encoder pulses are measured and, if excessive, a signal is sent to brake the traverse motor. Braking occurs if: the readhead detects a poor setup/alignment along the linear encoder track, see the Readhead section above. the Traverse PCB detects that the encoder is missing or not connected. A position error is generated if the carriage does not align with a reference point. a power failure is detected. The normal maximum speed of the carriage is 100 mm/sec which is measured from the carriage encoder signals. If the speed exceeds 110 mm/sec the brake is operated. A braking status message is available to the System PCB. Local ambient temperature around the Traverse PCB output devices is measured by an on-board sensor. If the temperature exceeds approximately 100 C, power to the motor is removed and a signal is sent to the System PCB.

4.2.3.2 Optical/Traverse Synchronisation

See Figure 4.8. The precision motion (PM) controller on the Traverse PCB requires a system clock that is scaled by a phase lock loop (PLL) and derived from the same crystal reference used for the spinner. This locks the spinner and traverse rates together, giving the exact resolution required. For lower resolutions the traverse moves at a correspondingly faster rate.

BEAMS

SCAN SWATHE A SCAN SWATHE B

Q P DRUM

Figure 4.8 Traverse and optical differences

Synchronisation of this kind is important for a dual-laser system where beam separation of the X and Y beams within a scan swathes (A and B) is determined optically by the spinner, but swathe separation is determined by traverse velocity. Any differences between optical and traverse scanning affects expose density and may give a raster defect. Synchronising should ensure that the distance at P matches the distance at Q. This principle of operation, when applied in practice, produces scan lines that are effectively at equidistance.

L UXEL P LATESETTER 2-4-17

4.2.3.3 Traverse Diagnostics

Traverse diagnostics, controlled from the Traverse PCB, check that the motor, power drive and linear encoder are connected and operating. There are also diagnostic commands to move the traverse in small incremental steps. Traverse encoding is constantly monitored by the board MPU while the motor is enabled. To avoid the possibility of damage to the system, the traverse registers in the PM controller are checked as a background task to ensure that: the scanning speed is within a specified range a new traverse position count has not deviated the linear encoder is sending valid codes and is working within its specifications. Other periodic and initialisation traverse checks are for: Home and Index sensor operation obstructions along the length of the track.

4.2.4 Traverse Initialisation Sequence

The board MPU runs a sequence of check routines to initialise the traverse system, after a reset or power up, in the following way:
1. Checks that a linear encoder is connected to the Traverse PCB. 2. If connected, then runs the on-board diagnostics.
A) B)

Checks for encoder alignment errors. Checks for the type of digital encoder and initialises the controller device accordingly.

3. Checks the status of the HOME signal to determine if the carriage is in the

Home region.

4. Sets up the PM controller to move in the appropriate direction. 5. Start the carriage movement in the direction set at step 4. above. 6. Stops carriage movement when a HOME signal is received; also, guards

against the signal being stuck at `0'.

7. Resets the traverse position counter to `0'. 8. Checks the INDEX signal is set to the correct value and guards against the

signal being stuck at `0'. initialisation.

9. Loads the traverse position counter with an offset to complete the traverse 10. Starts the spinner. 11. Checks that the spinner is rotating correctly and starts plate handling.

2-4-18 T RAVERSE S CAN M ODULES

4.3 Edge Detect System Description

CAUTION: The laser diode is a Class IIIB device. Follow the warning notices in Volume 1 Section 3.2.

4.3.1 Module Assemblies

See Figure 4.9. The Edge Detect module consists of the following assemblies: Edge Detect PCB: see Figure 4.10. Rear Traverse Bracket: see Figure 4.9 Laser Diode: wavelength at 405 nm with a mounting that allows for focus adjusting.
REAR BRACKET

FRONT BRACKET

LASER BRACKET

LASER

LED

PCB

PCB BRACKET

TRAVERSE BAFFLE

Figure 4.9 Edge Detect assemblies

4.3.1.1 Edge Detect PCB

See Figure 4.10.

Connectors
PL1: To STB fan power.

L UXEL P LATESETTER 2-4-19

PL2: PL3:

To STB To laser diode.

Connector Pin Descriptions

See Volume 2 Section 9.5 for a description of the cable interconnections.

PL1

PL2

PL3

LED

TP2 LASER TP4 (GND) VR1

Figure 4.10 Edge Detect PCB

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.

The sequence for detection operates as follows (see Figure 4.11):

1. A plate is loaded and makes contact with the two registration pins where

continuity is checked to ensure the plate is not skewed. switched ON.

2. The traverse starts moving from user to service end, and the laser is 3. When the plate edge is detected, the laser is switched off and the STB soft-

ware is informed.

4. The traverse moves a number of steps set by NVRAM parameter. 5. Imaging starts.

2-4-20 T RAVERSE S CAN M ODULES

2 3 4

IMAGE PLATE

DRUM

Figure 4.11 Edge detect operation

Volume-Chapt er

MEDIA EXPOSE MODULES

This chapter describes the optics system and the function of each main module.

5.1 Media Expose System

Media expose for all the Luxel CTP systems are based on a laser diode module generating light in the violet spectrum at 405 nm. Beams from two diodes, or pens, are combined using polarisation to provide a single emission. There is an option of one of a single- or dual-laser systems with an upgrade path between the two configurations. The media expose system consists of three main modules: Optics Base - includes laser modules, optics modules (EOD, etc) and the EODHV - see Section 5.1.1. Periscope and Spinner - see Section 5.1.3. Violet Boxer Optics Motor Board (VBOMB) - see Section 5.1.6. An outline introduction of how the Violet Luxel expose system, and its main PCB modules, function is given in Volume 1 Section 2.4. The Violet media expose system is able to operate under two lighting conditions:
1. Yellow safelight for Manual and Semi-Automatic machines - the plates are

5.1.1 Optics Base Modules

The base assembly, shown in Figure 5.2, is accurately mounted on the Engine frame and drum casting to ensure that a collimated beam exits at a pre-determined position. It is not designed to be field replaceable - so it is important not to remove or adjust the location of the base unit.

4 4

Media Expose System ................................................................................................ 5-1 Media Expose Control and Operation ....................................................................5-29

unpacked and exposed within a set time period. cassette and machine.

2. Office lighting for Automatic machines - the plates are fed into a light-tight

M2

L6

SPINNER

SM4 S3 L3 M3 POD BEAM SPLITTER L9

S6

LASER POWER DETECTOR SM2

FOCUS ADJUST

APERTURE POD

VOLUME 2 (5-2) M EDIA E XPOSE M ODULES

M1 L4 L2 S2 LASER DUMP S1 S5 SM3 L3 BEAM CONVERTER

L5

S4

L1 SM1 ND WEDGE FILTER

APERTURE CONTROL EOD X

Figure 5.1 Optics base - block view (2-beam)

LASER MODULE (X) BEAM SHIFTER WAVEPLATE LASER MODULE (Y) LASER TEMP/HUMIDITY SENSOR

BEAM COMBINER EOD Y

M3

L5

APERTURE CONTROL SM2 L9 M3 L1 POD APERTURE

GUIDE BEAM SLOT CONVERTER

FOCUS SM3 ADJUST

POD BEAM SPLITTER

EOD (X)

BEAM SHIFTER

ND WEDGE FILTER BEAM COMBINER SM1 EOD (Y)

LASER MODULE (X)

*
PHOTO DIODE PCB ELANTEC PCB

Figure 5.2 Optics base - module locations

VBOMB LASER MODULE (Y) WAVEPLATE * WAVEPLATE IS OPTIONALLY FITTED

TEMP/HUMIDITY MODULE

FAN M3

L UXEL P LATESETTER VOLUME 2 (5-3)

EODHV PCB

VOLUME 2 (5-4) M EDIA E XPOSE M ODULES

The base is divided into three separate working enclosures:

1.

Laser Diodes and VBOMB: single or two laser diode modules, each with Photo Diode (PD) and Laser Diode (LD) head boards. Image data, drive control, temperature and power control are provided by the VBOMB PCB housed underneath. Optics Modules: a set of beam processing devices between the laser diode and the base exit lens, L5. EODHV: supplies the deflected high voltage inputs to the two EODs.

2. 3.

Modules are mounted on a baseplate made from cast aluminium with pads and dowel pin fixing points that precisely locate them for accurate beam alignment. The base consists of three enclosures, each with its own removable cover. To prevent dust contamination inside the base, it is important that these covers are not removed unless a module replacement is required. When a cover is replaced, make sure all foam rings and seals inside the base are not disturbed. The following optics base modules are fitted as FRUs (Field Replaceable Units):
1. 2. 3. 4. 5. 6.

Laser Module EOD POD ND Wedge Filter Motors (SM1, SM2, SM3 and SM4) Sensors (S1, S2, S3, S5 and S6)

Remaining assemblies (beam combiner, lenses, mirrors, etc) on the base are not field replaceable. Each optic module on the beam path is accurately aligned during manufacture. If an optics module is replaced, it is usually necessary to run an optics_mmi setup procedure from Diagnostics to ensure that the new working part is correctly integrated into the expose system. See Volume 3 Section 4.4. After replacement, follow the recommended steps so that overall expose calibration is correct and within product specifications. Software control routines for base modules are run during the main operating stages for power on initialisation, expose setup, pre-scan and scanning. Resolutions operated by the Violet expose system are listed in Table 5.1.
Table 5.1 Luxel CTP VIolet resolutions Dots per Inch 1200 1219 1800 1828 2400 D/mm 47.2 48 70.9 72 94.5

L UXEL P LATESETTER VOLUME 2 (5-5)

Table 5.1 Luxel CTP VIolet resolutions Dots per Inch 2438 2540 3657 D/mm 96 100 144

5.1.1.1 Laser Module

WARNING: Once the covers are removed on the Luxel platesetter, radiated laser beams are classified as Class IIIB. With the covers in place, the laser operates as a Class1 source. Class IIIB lasers can only be serviced by engineers that have undergone a Laser Eye Test. Read all product laser Safety Notices before servicing laser equipment.

Laser Module Assemblies

See Figure 5.3. A Luxel system is configured as either:
A)

Single beam: using laser diodes LD3 (Y) only; there are two versions: upgradeable to dual-beam and non-upgradeable. Dual beam: using laser diodes LD1 (X) and LD3 (Y).

B)

The module is field replaceable. The Violet laser module comprises: Photo Diode (PD) PCB Laser Diode (LD) PCB Diode pen Beam correction lenses. The two laser modules (X and Y) are interchangeable. Each module is supplied with the two PCBs, Photo Diode and Laser Diode, already fitted. Control of laser output is from an Enable signal that is switched on when the system is scanning, and off when not scanning. The laser diode is directly modulated by image data from the VBOMB. Drive is provided for bias and data switching via the Laser Diode PCB. Laser power is measured from the LPD in order to achieve balance between the two beams.

Laser Input
The laser diode is driven by two current levels, bias and modulated drive data, shown in Figure 5.4. The addition of bias and drive current gives an output of approximately 25 mW. The power balance control from Phote Diode feedback vary the current slightly from the 30 mW setting. A separate Enable signal, set from the VBOMB control circuitry, serves as a laser shutter to halt beam emission.

VOLUME 2 (5-6) M EDIA E XPOSE M ODULES

LASER DIODE ELANTEC PCB PCB

LASER BLOCK

VIEW ON ARROW A

PELTIER

THERMISTOR PHOTO DIODE PCB PCB COVER

F60 LENS ASSEMBLY CYL 60 LENS ASSEMBLY CYL 22 LENS ASSEMBLY

LASER DIODE PHOTO DIODE PCB DISTRIBUTION PCB

MOUNTING PLATE LASER COVER

Figure 5.3 Laser module - general view

L UXEL P LATESETTER VOLUME 2 (5-7)

30 mW O/P POWER

DRIVE CURRENT (SWITCHED BY IMAGE DATA)

BIAS CURRENT IMAGE DATA FLOW

A)

IMAGE DATA

FEEDBACK

BIAS AND DRIVE CURRENT

B)

ONE FULL SPINNER REVOLUTION

Figure 5.4 Image and data input 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 gradually to compensate for the loss of power.

VOLUME 2 (5-8) M EDIA E XPOSE M ODULES

Laser Setup and Diagnostics

The supplied module is set up and calibrated at the factory before shipment. After a field replacement, the laser module must be set up again using the procedure in Volume 3 Section 4.4 onwards. A set of diagnostic checks that apply to the laser module are described in Table 5.2. See also Volume 2 Section 1.10.4.1.
Table 5.2 Laser diagnostic checks
Diagnostic Power Balance Check EODD OK X/Y Beam Enable/Disable Le(enable) Ld(isable) Laser Calibration Check LPD Power v ND Pos Description

Balancing of the two beams from the LPD using a defined ND value. Checks if the interlocks are closed for scanning. Switches beams on and off Enable X and Y lasers with parameters for bias and drive levels for each resolution. Disable X and Y lasers Checks drive level and remaining life for X and Y lasers Characterises LPD power readings against ND position.

Laser Temperature Control

See Volume 1 Section B.2 for a description of laser condensation control. Temperature control around the diode is set by: Two thermistor sensors (laser base and block) send temperature data to the VBOMB where it is used to modify Peltier temperature and provide a protection limit reading for the laser enable circuit. A Peltier holds the internal diode temperature at 25 C. Note that the fan is for cooling the VBOMB and not the laser modules.

5.1.1.2 Photo Diode (PD) PCB

See Figure 5.3. This PCB is located on top of the laser module.

Connectors
PL1: 20-way header to VBOMB.

Links and Test Points

There are no links or test points.

Operation
See Figure 5.5. A beam splitter on the output of the laser diode reflects a small percentage of the laser light onto a photo detect diode. It is measured once per spinner revolution and while the scanning beam is focused on the imaging area data is passed to the VBOMB to regulate laser power for beam balancing. Power supply to the PCB +15/-15 VDC.

L UXEL P LATESETTER VOLUME 2 (5-9)

The PD PCB is replaced as part of a new laser diode module.

CAUTION: Do not remove the PD PCB from the laser module.

5.1.1.3 Laser Diode (LD) PCB

See Figure 5.3. This PCB (includes an Elantec VLD device) is located at the back of the laser module.

Connectors
PL1: 20-way header to VBOMB

Operation
See Figure 5.5. This PCB supplies the drive current for the laser bias and switched data levels from the VBOMB. This drive is adjustable and is set by two separate VBOMB signals. Power supply to the PCB is +5 VDC and 7.5 VDC. These supplies are regulated from the +15 V output on the VBOMB. The LD PCB is replaced as part of a new laser diode module.

5.1.1.4 Laser Air Temperature and Humidity Control

A temperature and humidity module, located close to the laser module(s), monitors surrounding air inside the enclosure to prevent condensation on the laser block when the dew point level is raised. Volume 1 Section B.2.1 describes the operation of the module and Volume 1 Section 2.3 describes how it is replaced.

VOLUME 2 (5-10) M EDIA EXPOSE M ODULES

LASER POWER SENS LASER ASSEMBLY

PHOTO DIODE PCB

PELTIER

FAST AXIS

SLOW AXIS

APERTURE (1.5 mm)

1 mm x 1 mm THERMISTOR DIODE BEAM SPLITTER LF60 CYL22 CYL60

ENABLE

LASER DIODE PCB

TEMP SENS IMAGE DATA IN

DATA DRIVE LEVEL CURRENT CONTROL CURRENT LIMIT TEMP CONTROL PELTIER & THERMISTOR NOW GO VIA PHOTO DIODE PCB POWER CONTROL

BIAS LEVEL

TEMP LIMIT

OVER CURRENT/ OVER & UNDER TEMP/ OVER POWER PROTECTION VBOMB

Figure 5.5 Laser diode - beam control

5.1.1.5 Beam Shifter

See Figure 5.2. This module compensates for position errors as the two beams arrive at the beam combiner. It consists of a plane parallel plate tilted at 10 and rotated as a factory setting to change the beam position. The beam shifter is not always required on all machines. The beam shifter assembly is not field replaceable.

L UXEL P LATESETTER VOLUME 2 (5-11)

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.

5.1.1.7 Electro-Optic Deflector (EOD)

See Figure 5.6. Two EODs (X and Y) deflect the beams (X and Y) to compensate for spinner rotation. Both modules use high voltage drive provided by the EODHV board: EOD X: sine deflector. EOD Y: cosine deflector. EOD sine and cosine data are transmitted after addressing the deflector LUTs for each spinner revolution. During an expose, the EOD deflecting voltage levels are dynamically updated from the EODD.
CONNECTOR

WAVEPLATE

ALLEN CAPHEAD

BASEPLATE

Figure 5.6 EOD module - general view

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 EOD module is field replaceable.

5.1.1.8 Beam Combiner

See Figure 5.2. The main purpose of the beam combining prism is to merge deflected beams X and Y onto the same optical axis. It consists of one polarising prism appropriately positioned and angled so that the deflected beams are reflected onto the correct axis. Special optical coatings on each plate ensure that the optical power emerging from the module is nominally the same for each beam. This module is specially adjusted at the factory and is not field replaceable.

5.1.1.9 Neutral Density (ND) Filter

See Figure 5-5.7. A variable ND filter, attached to a wheel, filters the intensity (illumination) of the light beams to ensure that the correct exposure setting can be obtained. The positions of the wheel, in steps from a Home reference point, are derived during the expose calibration.
NOTE: The ND wedge must be cleaned with IPA.

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) STAY SENSOR BRACKET

ND FILTER

MOTOR BRACKET

FILTER WHEEL

MOTOR (SM1)

Figure 5.7 ND filter assembly - general view

5.1.1.10 Position Detector (POD)

See Figure 5.2. The main function of the POD board is to ensure that the two beams are co-incidental (aligned) within a margin of tolerance. This is done by measuring the relative position of each beam and providing compensatory offsets (change of DC bias voltages) using the EODs. Coincidence on the POD does not necessarily give coincidence on the drum. So, during an expose, further X and Y offsets are added to the LUT values for adjusting the two coincidence settings. Periodically, beam coincidence checks and adjustment routines are made via the detector when the system is in non-scan mode. To ensure correct measurements, the detector is accurately mounted (in relation to the beam axis) on a PCB and a mechanical holder. It is also pre-aligned at the factory before it is fitted in the optics base. A POD beam splitter of wedged glass reflects a small part of the combined beam back to the POD via L9 lens used for focusing the reflection and an aperture to prevent any secondary reflections. The POD is a field replaceable unit.

VOLUME 2 (5-14) M EDIA EXPOSE M ODULES

5.1.1.11 Focus Adjust

See Figure 5.8. A focus adjust lens moves backwards and forwards to give a fine focus adjustment for correcting small tolerance errors on the drum and different plate thicknesses. The lens is driven from a stepper motor (SM2) that moves in a number of steps depending on the thickness of the plates. SM2 drives a wheel that rotates 360 and also moves lens (L2) laterally along a pivotal axis in a leadscrew-type movement. One sensor (S3) is activated when the wheel approaches one end of the axis (Home), and another rotational sensor (S2) activates for a period during each 360 rotation. Note the focus difference between the green optics and the violet optics: Green: 1 step at focus (for 96 resolution) represents 0.345 m on the plate. Violet: 1 step at focus (for 96 resolution) represents 3.75 m on the plate. The focus adjust is not a field replaceable unit but it can be removed from the base plate provided it is accurately re-positioned against the dowels.
SENSOR (S2)

L2 LENS LENS BRACKET

SENSOR (S3) BEARING MOTOR BRACKET LEAD SCREW FLANGE BEARING MOTOR OPTICS BASEPLATE

HOOK

SPRING POST SHAFT FOCUS BASEPLATE

CLAMPING PLATE

Figure 5.8 Focus adjust - general view

L UXEL P LATESETTER VOLUME 2 (5-15)

5.1.1.12 Aperture Control (Spot Size)

See Figure 5.9. An aperture control changes position according to the resolution (144, 100, 96, 72, 48 l/mm) selected and so changes the spot size on the plate. At the 96 l/mm resolution, near to lens (L2), the beams provide the smallest spot size for the drum; as the mechanism moves towards lens L5 (using a pulley mechanism), the beam is clipped to provide 72 l/mm. The aperture is removed from the light path for the 96 and 48 resolutions and travels into position for 72 l/mm using a mechanical groove.

APERTURE BRACKET BEARING BRACKET CLAMPING PLATE

SLIDE ASSEMBLY

APERTURE

BEARING

L5 LENS ASSEMBLY (SEE NOTE)

APERTURE SLIDE BEAM CONVERTER BRACKET

TIMING PULLEY

BARREL FIXING BARREL SCREW SPRING

SENSOR (S5) BELT GUIDE SHAFT MOTOR (SM3) PIVOT SHAFT L3 V-BLOCK

BARREL ASSEMBL

Figure 5.9 Aperture control (and beam converter) - general view

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

Table 5.3 Aperture control settings

Resolution Spot Size (Approx) Converter State

48 72 96

25.4 - 31.8 16.6 - 20.8 <14

Barrel Lens IN, Aperture Out of Way Barrel Lens OUT, Aperture Clips Beam Barrel lens OUT, Aperture Out of Way

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.

5.1.1.13 Optics Lenses

See Figure 5.2 showing the location of each lens. Optics base lenses are not field replaceable and do not require cleaning as a service procedure. They function as follows:

Lens (L1)
Laser beam single lens used for focusing and collimating.

Lens (L2)
A single lens used for focusing and collimating.

Lens (L3)
L3-48 fixed in a barrel sets the 48 resolution from the beam converter mechanism.

Collimating Lens (L5)

A collimating lens mounted at the entrance of the periscope to ensure that the light travelling through the periscope and along the drum axis does not diverge or converge.

Focusing Lens (L6)

This lens is located on the traverse carriage and focuses the beams onto the drum surface via the spinner mirror. Lens L6 is only cleaned by the service engineer and not the customer. Once fitted on an installed machine it must not be adjusted.

Lens (L9)
Focus lens for the reflected beam on the POD.

5.1.1.14 Optics Mirrors

See Figure 5.2 showing the location of each mirror.

Mirror (M3 - A to C)
Three mirrors (A, B and C) deflect laser beams through an arrangement of optics sub-modules inside the base. The mirrors are aligned at manufacture to avoid reflective errors, and are also fixed to ensure that the two beams are parallel and

L UXEL P LATESETTER VOLUME 2 (5-17)

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.

5.1.1.15 Motors and Sensors

The following motors and sensors are fitted: ND Filter: SM1 and S2. Focus Adjuster: SM2 and S2/S3. Aperture Control: SM3 and S5. Laser Power Detector: SM4 and S6. All motors and sensors are field replaceable, but only some of the motors require a setup procedure after being replaced.

5.1.1.16 EODHV Module

Figure 5.2 shows the location of the module inside the optics base. The EODHV module provides the high voltage DC bias and AC drive for the electro-optic deflectors. The module consists of: PCB: see the EODHV PCB section below Transformers: see the HV Transformer section below.

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

PL1 X-BLACK

DC - DC CONVERTER

PL2 Y-BLACK

PL3 X-BROWN

PL4 Y-BROWN

TP1 TP7 TP4 X AMP X-VIOLET PL5 PL6 Y AMP

TP8 Y-YELLOW

X-YELLOW PL7 PL8

Y-VIOLET

TP10

LK1 1 2 3 OFF ON

PL9

TP11 TP12

Figure 5.10 EODHV PCB - layout view

Connectors
PL1: PL2: PL3: PL4: PL5: Push connector (black ident). X-channel HT supply. Push on connector (black ident). Y-channel HT supply. Push on connector (brown ident). X-channel HT supply. Push on connector (brown ident). Y-channel HT supply. Push on connector (violet wire). AC Modulation for X-channel.

L UXEL P LATESETTER VOLUME 2 (5-19)

PL6: PL7: PL8: PL9:

Push on connector (yellow wire). AC Modulation for Y-channel. Push on connector (yellow wire). AC Modulation for X-channel. Push on connector (violet wire). AC Modulation for Y-channel. 10-W Molex Minifit. Connection to EODD.

See Section 8.1.4 for details of the connector and signal descriptions from the EODD and the EODHV PCB.

Test Points
TP1: 12 VDC; TP4: X input (EODD); TP7: Y input (EODD); TP8: Y modulation; TP9: 24 VDC; TP10: X modulation; TP11:2 4 V GND; TP12: HV OK for both channels (active low).

Links
See Figure 5.10 (the default setting is ON). 1-2: HT OFF 2-3: HT ON.

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 primary 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 (BLUE TO RED SPOT) BLACK SLEEVE BLACK (HT) BROWN (HT) (PUSH ON)

TO EOD (X OR Y)

TRANSFORMER

VIOLET/YELLOW (PRIMARY)

Figure 5.11 EODHV transformer assemblies

VOLUME 2 (5-20) M EDIA EXPOSE M ODULES

Transformer - Secondary Resistance Check

See Figure 5.11. To check the two secondary windings on a transformer, use a DVM (on ohms setting) and measure the following: Black wire to Pin 1 of EOD connector (pin next to red spot): 140 ohms (approximately) is the correct reading. Brown wire to Pin 2 of EOD connector (away from red spot): 140 ohms (approximately) is the correct reading.

5.1.2 Optics System Configurations

The optics system is fitted as two versions:
1. 2.

Two-beam: this system uses lasers (X and Y) and all the modules shown in Fig Figure 5.2. One-beam: this uses a single laser and has the following modules removed:
A) B) C)

Laser diode (X) EOD (X and Y) Beam Combiner.

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.

5.1.3 Periscope Assemblies and Operation

See Figure 5.12. A periscope arrangement redirects beams from the optics base to the spinner. It is not a single assembly but functions as three sub-assemblies: M1: (optics base end) - see Section 5.1.3.1. Laser Power Detector (LPD): see Section 5.1.3.2. M2: (spinner end) - see Section 5.1.3.3. A removable cover between the two mirrors protects the LPD sensor from dust and prevents small changes of air temperature from affecting the beam.

L UXEL P LATESETTER VOLUME 2 (5-21)

M2 ASSEMBLY

LASER POWER DETECTOR (SEE FIGURE 10.19)

M1 ASSEMBLY

OPTICAL BEAM

Figure 5.12 Periscope assemblies - general view

5.1.3.1 Top Mirror (M1) Assembly

This mirror directs the beams through the periscope towards mirror (M2). It is setup at the factory and is not field replaceable.

5.1.3.2 Laser Power Detector (LPD) Assembly

A laser power detector assembly, located between M1 and M2, rotates a concentrating lens to focus the beams onto a large area detector. It includes a motor (SM4) and a sensor (S6). While the system is not scanning, the laser is switched on and average beam power for X and Y beams are measured. The purpose of these measurements are: Beam balance: any power difference between the two beams is equalised by adjusting the laser current drive for the stronger beam to match the weaker beam. Operation: each beam is checked for correct operation as a diagnostic procedure. The LPD also acts as a shutter when closed inline with the beam. It includes a manual safety shutter allowing the engineer to investigate a problem inside the drum while the optics system is active. The limit sensor (S6) detects when the LPD mechanism has reached its Home position. The motor has a 3:1 gear reduction to give finer control over the position of the sensor.
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 SUPPORT LENS AND FILTER MOUNT

FILTER CLIP

MANUAL SHUTTER

DETECTOR PCB

POWER LENS

ND FILTER AND 'O' RING MOTOR SUPPORT MOTOR (SM4) PULLEY SHAFT

TIMING PULLEY

Figure 5.13 Laser Power Detector assembly - general view

5.1.3.3 Bottom Mirror (M2) Assembly

This mirror assembly is set at the factory for coarse and fine optical alignments. Coarse settings are not field-adjustable; fine settings may be adjusted to correct for errors (after, for instance, replacing a spinner) if the registration checks indicate a problem. See Section 4.7.2.1 for information about the registration (image form) correction procedure.

L UXEL P LATESETTER VOLUME 2 (5-23)

M2 BRACKET ADJUSTING SCREW

M2 MIRROR

ADJUSTING SCREW

HOUSING

Figure 5.14 M2 Mirror assembly - general view

See Section 4.7.2.1 for a description on how to adjust M2 for correcting image form errors.

5.1.4 Spinner Assembly and Operation

WARNING: If the interlocks are overridden when the end panels are removed, make sure the spinner is not rotating during a service procedure.

The spinner currently specified comprises a mirror, shaft, body, motor, encoder and cables.
NOTE: The spinner mirror is metal-based with a special reflection-enhancing coating. Always use the cleaning procedure described in Volume 3 Section 1.5.1..

A single facet mirror, angled at approximately 47.5, rotates at the following speeds to reflect light to the plate surface from the periscope: 10,000 rpm idle speed. 33,333 rpm (556 Hz) for 48 and 47.2 (1200 dpi): Operates at a slower speed in order to get sufficient power to image.

VOLUME 2 (5-24) M EDIA EXPOSE M ODULES

Use diagnostics command: Spinner> start 33.

40,000 rpm (667 Hz) for all other resolutions. Acceleration from rest to full speed is less than 20 seconds, and from idle speed to full speed approximately 10 seconds. The carriage only traverses when the spinner is stationary or at full speed.
CO SIGNALS MOTOR DRIVE SIGNALS MIRROR SURFACE

LASER BEAM

The assembly consists of a shaft supported on air bearings and rotated by a brushless DC motor. The bearing air supply is internally generated by the motor. Spin speed is at all rates with drive current supplied from 36 VDC. Spin direction is always anti-clockwise (looking from the mirror end). At one end of the shaft an incremental encoder, operating from a 5 V supply, generates the following signals for System Board image data control: rotational frequency (SPIN INDEX) at one per revolution angular position data (DATA A) with a resolution of 720 lines per revolution. Three Hall effect sensors are located in the spinner. When the spinner accelerates, these sensor signals (with 120 timing) indicate the rotor position; they are decoded by the spinner controller to commutate the drive currents to the correct switching sequence. In a steady state, commutation operates internally without the need for sensor signals. The spinner has two cable interface connections: spinner motor signals (12-pin Molex) spinner encoder signals (8-pin Molex). This assembly is a field replaceable unit and includes a cleaning procedure for the mirror. A replaced spinner assembly must be returned to FFEI Customer Support (UK).

DEFLECTED LASER BEAM

SPINNER MOTOR

ENCODER

Figure 5.15 Spinner assembly

L UXEL P LATESETTER VOLUME 2 (5-25)

5.1.5 Fast Photo Detect (FPD)

See Figure 5.16. An FPD sensor (BS21), located behind the drum (service end, input side), has two functions:
1. Compares the power at the drum to the power at the LPD to determine the

extent of contamination. at the drum.

2. Measures laser power during exposure calibration to set the requested level

Details of these two machine features are in the Luxel Operators Manual. The sensor and the ND filter must be kept clean to give accurate readings. See Volume 3 Section 4.2.9 for the full replacement and setup procedures to ensure that the exposure calibration is accurate.

DRUM SERVICE END

INTERFACE CONNECTOR TO FHMB4 NEUTRAL DENSITY FILTER PHOTO SENSOR BOARD ASSEMBLY

FPD MOUNT

Figure 5.16 FPD - location view

VOLUME 2 (5-26) M EDIA EXPOSE M ODULES

5.1.6 Optical Motor Control PCB (VBOMB)

The VBOMB is a CAN node PCB that controls optics exposure on command from the LSB. Volume 1 Section 2.4.3.1 describes how the VBOMB operates with its main functions as: channelling image data from the LSB to the laser module controlling the optics base stepper motors detecting the current status of the motors for Home and Limits providing drive control circuitry for the laser module providing laser diode temperature control setting laser diode temperature stability.
NOTE: For early application software releases, the laser current limits must be manually set at each service visit using the procedure in TIS 13887.

5.1.6.1 Optical Motor Control PCB Assembly

See Figure 5.17.

Location
Lower interior of the optics base, see Figure 5.2.

Connectors
PL1: PL2: PL3: PL4: PL5: PL7: PL8: PL9: PL10: PL11: PL12: PL13: PL14: PL15: PL16: PL17: PL18: SK1: 10-way. Not used. 40-way. Not used. 10-way. LPD sensor detector. 8-way. Not used. 14-way. POD sensor. 10-way. Not used. 5-way. Envir I/P from laser temperature/humidity PCB. 40-way. Laser (X). 40-way. laser (Y). 10-way Molex minifit. +5V, +15V, +24V and -15V DC supplies from the PWR FILTER PCB. 3-way. Fan. 24-way. Motor sensor inputs. 6-way. ND Filter motor drive. 6-way. LPD motor drive. 6-way. Aperture control motor drive. 6-way. Focus motor drive. 6-way. Not used. 8-way. Image data

L UXEL P LATESETTER VOLUME 2 (5-27)

SK2:

15-way. CAN1.

The cable connections to the VBOMB PCB are described in Figure 9-9.3, showing the system interconnections, and Appendix A listing the pin signals.

PL8

PL5

PL3

PL9 (x)

PL12

PL10 (y)

TP6 +15V

PL13

FRONT VIEW

SK1 PL11

FS1 PL14 LK1 PL15 PL1 PL16 TP1 +5V PL17

PL18 PL2 SK2 LK2 PL7

Figure 5.17 Optics Motor Control PCB (VBOMB) layout

Fuses
FS1: 3A slow-blow (97280015).

VOLUME 2 (5-28) M EDIA EXPOSE M ODULES

Links
LK1: LK2: Link is removed. Link is removed.

5.1.7 Optics Base Cabling

Figure 5.18 shows the cabling between the optics base modules and the VBOMB. These cables are carefully routed and tied as looms and should not be disturbed. If a cable replacement is required, make sure there is a minimum of alteration to the loom routing.
LASER (x) LD1 VBOMB_IHPEN LD PCB PD

LD PCB

LASER (y) LD3 VBOMB_IHPEN LD PCB PD

RFI BOX LSB VBOMB_LPD

CAN1

PL9 SK2

PL10

PL3 PL15

VBOMB_LPDM LPD

HOME S6

LSB_DATA

SK1 VBOMB

PL14

VBOMB_NDM

ND FILTER

HOME S1

POWER FILTER

VBOMB_PWR

PL11

PL16

VBOMB_ADM

APERTURE

HOME S5 S3 HOME FOCUS LIMIT S2

VBOMB_POD

PL5 PL8 PL12 PL13

PL17

VBOMB_FOCM

FOCUS

POD

VBOMB_ ENVIR_ MON TEMP/ HUMIDITY MODULE

VBOMB_SENSORS

VBOMB_FAN

FAN (VBOMB)

Figure 5.18 VBOMB cable interconnections

L UXEL P LATESETTER VOLUME 2 (5-29)

5.2 Media Expose Control and Operation

5.2.1 Expose Sequence
The following operations are performed during an expose operation: Load a plate into the drum. Start up the spinner. Close the LPD to prevent exposing the plate. Switch on the lasers in bias mode. Perform cage creep compensation if required. Move the traverse to the start of scan position. Adjust the ND position to set the power level depending on resolution. Adjust the focus position depending on plate thickness. Adjust the aperture to set the spot size depending on resolution. If resolution has changed, then perform power balance. Apply sinusoidal deflection to the beams. Open the LPD shutter. Start the traverse. Modulate the lasers with image data. At end of expose, stop the traverse. Perform cage creep compensation if required. After a timeout, stop the spinner.

5.2.2 System Calibration

The following operations are performed every 1.5 hours if an expose job is requested:Check power balance and adjust if required Check beam_co and adjust if required.

The following operation is performed every 24 hours if an expose job is requested: Check for laser aging and adjust the laser current limits if required. Check and adjust the ND settings for all 8 resolutions to give the correct exposure calibration. The following operation is performed on demand by the user from the MMI:

5.2.3 Expose Control Functions

See Figure 5.19. The following expose control functions are used:

4 4 4 4

VOLUME 2 (5-30) M EDIA EXPOSE M ODULES

EOD deflection. Laser aging control. Power balance. Beam coincidence. Drum coincidence. Exposure Calibration.

5.2.3.1 EOD Deflection

With no EOD deflection, the 2 beams will be on top of each other all the way around the drum. If a static deflection is applied, the beams separate in the slow scan direction at one point on the drum. At 90 degrees spinner rotation, the beams are separated in the fast scan direction instead. At 180 degrees spinner rotation, the beams cross over and separate in the slow scan direction again. To make the beams run parallel, a compensating sinewave deflection is added to the EODs. The X-EOD has a sinewave deflection and the Y-EOD has a cosine wave deflection. Static deflection is used to get co-incidence of the beams on the drum after beam coincidence is obtained on the POD. Sinewave deflection is used to separate the beams in the slow scan direction to get even spacing of lines. The amplitude of the sinewaves are adjusted to get the correct spacing at all resolutions. The absolute phase of the sinewaves i.e. the phase relative to the spinner index is adjusted to maximise the deflection in the slow scan direction. The LSB generates the deflector sinewave LUTs. This digital data is passed down the EODD bus to the EODD board and converted into low voltage sine and cosine waveforms using DACs. This is then passed to the EODHV board which generates the high voltage signals required for the EOD deflectors.

5.2.3.2 Laser Aging Control

The laser has an integral photodiode detector board. This is used in a negative feedback loop to control the laser output power in APC (Automatic Power Control) mode. The current taken by the laser diode is adjusted automatically to give the correct power. As the laser ages, the current required increases to give the same power output. The laser has a current limit which is set at 10% higher than the operating current. As the operating current increases, the current limit has to be also increased to prevent current limiting. The laser aging control loop is executed once every 24 hours. This checks the operating current of each laser and changes the current limit to give a 10% margin. The rate of change of current is checked. If this exceeds 7% in 24 hours, then a serious warning is given on the MMI that a laser change is required urgently. When the operating current reaches 50% higher than the original operating current when the laser was new, then a less serious warning is given on the MMI that a laser change is required within a few weeks. Each time the laser current increases by 10%, an entry is added to laser statistics tables in diagnostics. The table is capable of holding 5 pairs of data values. By inspecting this table, the rate of laser aging can be calculated and a prediction made of when the 50% overcurrent will occur.

L UXEL P LATESETTER VOLUME 2 (5-31)

SPINNER M2 STB CAN

TO LUXEL SYSTEM BOARD

LPD VBOMB M1 PERISCOPE

TO DRUM SURFACE POSITION DETECTOR (POD) ND WEDGE FILTER

APERTURE

FOCUS

VBOMB OPTICS BASE LASER (X)

VBOMB EOD (X)

VBOMB

BEAM COMBINER

LASER (Y)

EOD (Y) TRANSFORMERS X/Y

PD AND LD PCB

IMAGE DATA & CONTROL

PD AND LD PCB DRIVE/POWER CONTROL

EODHV

APERTURE FOCUS POD ND TEMPERATURE/ HUMIDITY SENSOR BOARD

LPD

VBOMB

EODD

CAN CAN

IMAGE DATA CONTROL

STB

LUXEL SYSTEM BOARD

RFI BOX IMAGE DATA SCSI DIAGNOSTICS (RS232)

RIP SERVER

Figure 5.19 Expose control - top level block view

VOLUME 2 (5-32) M EDIA EXPOSE M ODULES

5.2.3.3 Power Balance

The purpose of power balance is to get equal powers in both beams at the drum. The actual powers are measured at the LPD since the transmission loss is the same for both beams between LPD and the drum. Power balance depends on resolution. If a job is requested and if there is a resolution change or if a 1.5 hour timer has expired, then power balance is checked. If the powers are within limits, then the job is exposed. If the powers are outside tolerance limits, then the powers are adjusted. Power balance is achieved as follows: Set both laser drive powers to maximum (25 mW at the output of the laser module). Set the optics motors to the 96 resolution position. Check the power levels on the LPD. For the laser with the highest power, reduce the drive power until the powers are equal. The powers are adjusted separately for 3 different optical models. The LOW resolution model is for 1200 and 48 resolutions which has the drop down lens in the beam converter (aperture mechanism) to give the largest spot size at the drum. The MID resolution model is for 1800 and 72 resolutions which has an aperture in the beam to give a mid size spot at the drum. The HIGH resolution model is for 2400, 96, 100 and 144 resolutions which has no aperture to give the smallest spot size at the drum.

5.2.3.4 Beam Coincidence

The purpose of beam coincidence (beam_co) is to get the 2 beams to be coincident (on top of each other) at the POD. The X deflector can only deflect the beam in the X direction i.e. horizontally when viewed on the POD (assuming the optics base is in the machine). The Y deflector can only deflect the beam in the Y direction i.e. vertically on the POD. The result is that at coincidence, the beams will normally not be exactly centred on the POD. The beams will be within 100 m of the POD centre for a new machine but may be up to 200 m from the centre after optics modules are replaced in the field. Beam-co is achieved as follows: Adjust the powers in the X and Y beams to be 200 W on the POD. Measure the positions of the X and Y beams on the POD (X1 and Y1 in Figure 5.20). Deflect both beams by a small amount. Measure the new positions of the X and Y beams (X2 and Y2 in Figure 5.20). The coincidence point is where the lines on the graph cross. Calculate the deflection required to make the beams coincident. Adjust the deflection and check the accuracy of coincidence. If outside tolerance limits, repeat beam_co until within limits. Update NVRAM parameters EODD_LB_X_OFFSET_FULL_POWER and EODD_LB_Y_OFFSET_FULL_POWER in NVRAM with the new deflector

L UXEL P LATESETTER VOLUME 2 (5-33)

drive values.
Y

Y2 COINCIDENCE POINT

X1 Y1

X2

POD DETECTOR

Figure 5.20 POD beam_co measurements

5.2.3.5 Drum Coincidence

When the beams have been made co-incident on the POD, there may still be a small offset between the beams at the drum. This is corrected by adding small X and Y static offsets to the deflector drive values calculated from beam_co. The required offsets are measured by running the Co-incidence X and Y test patterns from the Optics MMI and the results are stored in the Final Values table.

5.2.3.6 Exposure Calibration

The purpose of Exposure Calibration is to set a constant energy density level measured in J/cm2 at the drum. At lower resolutions, for example, 48l/mm, since the traverse is moving more quickly than at 96l/mm, more power is required to achieve the same energy density. The power level is measured directly at the drum using a Fast Photo Detector (FPD). The FPD is mounted behind the drum at the service end and a hole in the drum allows the beam from the spinner to pass through. As the spinner rotates past the FPD, the pulse of power is converted to a photodiode current. This is passed to FHMB4, converted to a DC voltage level and then read by an ADC. Exposure calibration is affected by spinner contamination or optics aging, both of which degrade over a long period. Exposure calibration is not affected by temperature or humidity. Therefore, exposure calibration only needs to be run once per week or if the spinner mirror has been cleaned. Exposure calibration is run from the MMI. Exposure calibration works as follows:
1. Start the spinner. 2. Move the traverse to the FPD position which is defined in

VOLUME 2 (5-34) M EDIA EXPOSE M ODULES

TRAV_HIGH_SPEED_POS
3. 4. 5. 6. 7. 8. 9.

Set the optics motors to 48l/mm. Measure the powers in the X-beam and the Y-beam. Calculate the ND adjustment required to give the correct exposure at 48 res. Calculate the ND offset to give the correct exposure for 1200 res. Set the optics motors to 72l/mm. Measure the powers in the X-beam and the Y-beam. 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

POWER AND CONTROL MODULES

This chapter describes the main power and control assemblies and interconnections:

6.1 Introducing Power and Control Modules

Power and control functions for the the plate handling, optics and vacuum sub-systems are as follows: System Power Distribution: shows how AC and DC voltages are distributed around the Engine, PTM and Buffer. Interlock Box Modules: explains how the interlock and emergency stop circuits operate. RFI Box PCBs: describes the main control PCB for the CAN network, the electrodeflection control PCB and the filter PCB for the DC voltages and interlock signals. Hard Disk Drive (HDD): describes the function image disk buffer and Man-Machine Interface (MMI): the console control interface. External Alert: a description of a customer option for setting up a laser external alert in the platesetter room.

6.1.1 Accessing Engine Assemblies

Power and control sub-systems are housed on the Engine with access shown in Figure 6.1. Note that these modules have a common location for all variants. RFI box: located at the rear of the Engine on the service side. Remove the box cover

4 4 4 4 4 4 4

Introducing Power and Control Modules ................................................................. 6-1 System Power Distribution ........................................................................................6-2 Interlock Box Modules ...............................................................................................6-6 RFI Box Modules ...................................................................................................... 6-16 RFI Box - DC Power Modules ..................................................................................6-19 RFI Box - Image Processing Modules ....................................................................6-23 MMI and External Alert .............................................................................................6-30

VOLUME 2 (6-2) P OWER AND C ONTROL M ODULES

(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 SIDE

SERVICE SIDE

POSIDRIVE SCREW (18-OFF)

RFI BOX

Figure 6.1 Accessing the power and control assemblies (fully-automatic)

6.2 System Power Distribution

AC supply is fed directly to a mains filter box before it is routed directly to: PSU 1 in the RFI box for generating DC voltages PTM and Autofeeder Vacuum pump and compressors (after relay switching).

6.2.1 AC Mains Power Pre-Requirements

Voltage supply to the platesetter must conform to the site pre-requirements given in the Luxel Platesetter Pre-Installation Manual. A summary of these requirements are:
1.

A standard build platesetter operates with:

A)

230 VAC single-phase volts 177-264 at 47-63 Hz.

L UXEL P LATESETTER VOLUME 2 (6-3)

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. Other platesetter equipment (PAT, processor, RIP PC and plate stacker) have separate AC supply points.

C)

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 distribution supply for the platesetter. The type of fuse protection should be within local regulations. Recommended rating for the fuses are:

V-9600 CTP Fully-Automatic: 16 A Vx-9600 CTP Fully-Automatic: 16 A V-9600 CTP Manual and Semi-Automatic: 10 A Vx-9600 CTP Manual and Semi-Automatic: 10 A V-6000 CTP Manual and Semi-Automatic: 10 A Vx-6000 CTP Manual and Semi-Automatic: 10A 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) B)

The platesetter requires a dedicated system earth via a common earth point. 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 equipment.

6.2.2 Mains Filter Box

See Figure 6.1. This unit is located on the service side underneath the interlock box. Note the warning below:
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.

6.2.3 System AC/DC Cable Distribution

See also Volume 2 Chapter 2-10 for views of the AC/DC cable interconnections and Volume 2 Section 8.1 for a description of the cable pin voltages and signals. A single mains supply to the two PSU (1 and 2) is controlled by an ON/OFF switch on

VOLUME 2 (6-4) P OWER AND C ONTROL M ODULES

the Engine and two emergency stop buttons on the PTM. While the emergency stop circuits 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.

6.2.4 System DC Cable Distribution

See Figure 6.2 and Figure 6.3 This section describes the DC voltages and cabling to the modules and devices (sensors, motor, etc) from the PSU in the RFI boxes. It also shows the PCBs that generate/convert on-board DC voltages for local use. Distribution PCBs are employed to optimise machine cabling. Sensor Distribution PCBs are non-active and serve as +5 VDC supply to the standard plate opto-reflective sensors 24 V Distribution PCBs include active devices to attenuate sensor outputs and channels +24 V to sensor devices that require a +24 V supply.

+24V +36V (24V_ENG) I/LOCK BOX +5v +36V +24V (UMB) STB TRAVERSE +36V SPINNER READHEAD MOTORS

+24V +36V (PWR2)

TRAV MOTOR

RFI BOX MAINS IN +5V +5V +5V +24V +24V AC +24V FHMB4

AC (MAINS_RFI_IN)

MOTORS SENSORS

+5V +24V +15V -15V (ENG_FHMB PWR) +5V +24V SENSOR DIST AND 24V DIST

BUFFER
SENSORS SENSORS +5V SENSORS MOTORS

(EOD)

+12V +24V +5V FHMB1 +5V +24V

+24V +5V (SEE BOX)

EODHV

SENSOR DIST

VBOMB

(EOD) +24V +24V (PWR3)

+12V FHMB3 +5V +5V +24V/+5V SENSOR DIST +5V

2kV

SENSORS +24V 24V DIST +5V

EOD 1/2

LASER

SENSORS SENSORS FHMB2 +5V +24V TO AUTOFEEDER MOTORS

Figure 6.2 DC distribution - Engine, PTM and Buffer

POD +/-15V LPD +/-15V

LASER

L UXEL P LATESETTER VOLUME 2 (6-5)

OPTICS BASE

PTM

VOLUME 2 (6-6) P OWER AND C ONTROL M ODULES

FHMB2

+5V (RIB8)

ELEVATOR DISTRIBUTION

+5V (ELV_LOCK)

SENSORS +24V +24V CASSETTE DOOR LOCK +24V ABS LMT CONTACTOR_24V (ELV_LOCK) CONTACTOR Z-DIRECTION DOCKING LIGHT

FHMB2 (INT_OUT)

MOTOR CONTROL

ELEVATOR MOTOR ELEVATOR CONTROL

+24V AC INVERTER AC

PTM MAINS

AUTOFEEDER

Figure 6.3 DC distribution - Autofeeder

6.3 Interlock Box Modules

WARNING: Always remove the mains power lead first before servicing the mains filter box.

6.3.1 Interlock Box Functions

See Figure 6.4 and Figure 6.5.
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.

6.3.2 External I/O Interconnections

See Figure 6.5.

INTERLOCK FUSEHOLDERS AND 3-OFF FUSES INTERLOCK CONTACTOR INTERLOCK MONITORING MODULE DISTRIBUTION TERMINAL BLOCK END STOP COMPRESSOR RELAY (BV31) PWR 1 INTERLOCKS

SHUTTER (LASER ON/OFF)

NL N L RAIL

SURGE SUPPRESSOR PWR 3 PWR 2

PSU (30W +24V) LINKS PSU MAINS COVER

POWER IN EMERGENCY VAC

ON/OFF SWITCH (CIRCUIT BREAKER & RELEASE COIL) VAC PUMP RELAY (BV5) PUMP (2) (MAINS TO PTM) MAINS_DIST (FROM MAINS FILTER)

24V FUSE (0.5A 250V)

VAC OVERCURRENT CIRCUIT BREAKER (8A)

LED DIAGNOSTICS MAINS_RFI_IN (MAINS TO RFI BOX) COMPRESSOR BOX (MAINS TO COMP)

PUMP (1) (MAINS TO VAC PUMP)

Figure 6.4 Interlock box assemblies - location view

VOLUME 2 (6-8) P OWER AND C ONTROL M ODULES

INTERLOCKS

SHUTTER (LASER ON/OFF)

PWR IN

VAC PUMP CIRCUIT BREAKER RESET BUTTON

EMERGENCY

PWR 2

PWR 3

PWR 1

Figure 6.5 Interlock box - connector layout

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. 2. 3. 4. 5.

VAC PUMP CONTROL: input from FHMB4 controls the vacuum relay to switch mains supply to the drum vacuum pump while the system is scanning. PWR IN: input from +36 and +24 VDC supply, via the Power Filter PCB and the laser EODD interlock control signals. INTERLOCKS: input from interlock panel sensor connections to the box interlock controls. EMERGENCY: emergency stop circuit to/from the PTM via ENG_FHMBPWR. PWR 1: output cable for +24 VDC to FHMB(1) via ENG_FHMBPWR.

VAC PUMP CONTROL

FUSE 24V (0.5A 250V)

L UXEL P LATESETTER VOLUME 2 (6-9)

6. PWR 2: output cable for +24 and +36 VDC to FHMB(4). 7. PWR 3: output cable for +24 VDC to FHMB(2 and 3) via ENG_FHMBPWR.

AC Power inlet and distribution is via five cable glands on the interlock box shown in Figure 6.4.
1. MAINS_DIST: AC voltage direct from the mains filter. 2. MAINS_RFI_IN: emergency-protected AC supply to the RFI box for generating sys-

tem DC voltages.
3. PUMP (1): AC power supply for the drum vacuum pump controlled from the vac-

uum drum relay inside the interlock box.

4. PUMP (2): AC power supply for the plate feeder and elevator motor. 5. COMP_MAINS: AC power is supplied, via a relay (BV31), to the drum blow com-

pressors in the compressor box.

6.3.3 Mains Input and Emergency Stop Control

Figure 6.6 shows the circuit wiring for the mains input and emergency stop system.

6.3.3.1 Mains Input Control Assemblies

Circuit Breaker and Undervolt Detector (15A)
This is an On/Off (2-pole) rocker switch/circuit breaker for the operator that includes under-voltage release coil (for the emergency stop circuit) and short-circuit protection. The main circuit breaker is tripped in the event of a loss of voltage. To reconnect the load, the switch must be reset so as to avoid the automatic restart of the machine.

24 V PSU (Emergency)
A +24 V (30 W, 1.2 A) dedicated supply for the emergency stop circuit. It includes a selectable transformer setting for 240/110 VAC at 47-63 HZ. The AC input is protected by fusing; there is also overvoltage protection. Output regulation is <0.1 %.

Fusing
See Section 6.5.3.

Emergency Stop Control

See Figure 6.6. This facility is for use by the engineer or operator to power off the machine during an emergency. The switch is fitted to the PTM (fully-automatic) and on the Engine (manual and semi-automatic).
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.

2 5 1 +24V EMERGENCY STOP

6 WAY CONNECTOR

99700424

99700243 TERMINAL BLOCKS 99700447

+24 VDC NEUTRAL 24V GND +24V 2 LINKS NEUTRAL WIRES SOLDERED TO PSU 99700444 99700444 1 3 LIVE CONNECTOR 99700310 +24V CONNECTOR LIVE

NOTE: 0455 FEEDS INTO TOP OF TERMINAL BLOCKS. 0122 FEEDS INTO BOTTOM OF TERMINAL BLOCKS

CIRCUIT BREAKER + UNDERVOLTAGE COIL

ENG 24V_GND ENG 24V 4

SIE A2 SIE 21NC

VOLUME 2 (6-10) P OWER AND C ONTROL M ODULES

C/B N L (OUT)

99700444

LINKS

99700455 (NOTE)

BV31 (FHMB4) SEE 'A' 4 VAC PUMP 24V RELAY (BV5) 7 9 B 99700444 6 A

COMP 24V RELAY (BV31)

+OUT 24V DC SUPPLY 4 -OUT

09700310

EARTH CONNECTED TO CASE

99700454

99700424

0.5A FUSE

99700122 (NOTE)

8-WAY CONNECTOR PIN 2 99700456 CHASSIS PIN 6 PIN 1 BV5 (FHMB4)

CHASSIS CHASSIS

CHASSIS

VAC CIRCUIT BREAKER (5A) CHASSIS

Figure 6.6 Interlock box - mains wiring, vacuum and emergency stop control
'A' MAINS TO PUMP (ENGINE) 99700150 LIVE & NEUTRAL FROM MAINS FILTER 99700243 'A' PIN 4 PIN 8 BV31 (FHMB4)

MAINS TO COMPRESSORS

MAINS TO RFI BOX 99700122

MAINS TO PTM 99700150

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.

Emergency Stop Replacements

If any component of the emergency stop circuit is replaced or altered, the stop operation must be fully verified before the system is restored to the customer.

6.3.4 Drum Vacuum Control

See also Volume 2 Figure 7.1.

Relay
A 25 A DPDT relay at 24 V. Control is from FHMB4 that switches the relay when vacuum is required to conform a plate to the drum prior to a scan.

Circuit Breaker (Thermal)

This is a two-pole, 8 A breaker used to protect the drum vacuum circuit. Push in to reset circuit breaker.

6.3.5 Interlocks Control

This section applies to all variants. This section provides further information for the engineer to service the interlock system. Refer to Volume 1 Section 3.3 for interlock safety warnings and Volume 1 Section 3.16 the location of the cover sensors. See 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. See also Volume 2 Section 3.2.1 for a description of the Autofeeder interlock control circuit.

Interlock Box Assemblies

The interlock sensor system operates as a feedback loop circuit with a keyswitch (Normally Open contact) to enable the circuit. Supply voltage to the circuit is +24 V. Interlock sensors (and the external laser door switch) return a signal to the safety relay located inside the interlock box. The main interlock assemblies are: Sensors: interlock sensors on the platesetter and an external sensor that controls the

VOLUME 2 (6-12) P OWER AND C ONTROL M ODULES

DLA (Designated Laser Light) for the platesetter room. Safety relay (Schmersal AES1235): this monitors the status of the interlock sensors and operates two microprocessor-controlled relays switch on/off drives for the: +24 VDC supply to the two interlock contactors on the Engine and the Autofeeder. See below for a description of the AES 1235 operation. Contactor (Siemens 3RT1016): when energised from the safety relay 24 V supply, it closes the following contacts:
A) B) C)

+24 V to the FHMB motor drives. +36 V to the spinner. laser interlock status control to the EODD. +24 V to the safety relay (contactor confirm).

and opens the following contact:

D)

Since the contactor forms an inductive load it requires a separate plug-in surge suppressor. A contactor of the same type also controls the AC supply to the elevator motor. See Volume 2 Section 3.2.1 for the Autofeeder contactor. Fuses (F1 to F3): protect the +24V input and the interlock feed circuit. Fuse rating is: 1 A, 250 V. Interlock Override Keyswitch: located on the Engine. While the key is inserted it is not possible to shut the service side cover. Setting the switch bypasses the cover interlock sensors and the external interlock. It opens an NC contact that alerts the LSB to indicate (on the MMI) that the interlocks are in an overridden state.

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 contactors, 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)

A) B) C)

+24 V to the safety relay to confirm it has operated +24 V to the FHMB and STB +36 V to the STB

Autofeeder Contactor: when energised by the +24 V from the safety relay contact, routes the 3-phase mains from the inverter to the elevator motor. A contactor confirm signal is routed to FHMB2. When the safety relay detects an unsuitable condition (cover open or external interlock problem AND interlocks NOT overridden), the two safety relay contacts are opened. They put the machine in a safe condition as follows: +24 V from the Power Filter PCB to the two interlock contactors is cut off:
A)

Interlock box contactor drops out and: safety relay detects that the contactor has dropped out +24V is not supplied to the FHMBs and STB (operator accessible motors cannot move) +36 V is not supplied to the STB (the spinner cannot move).

B)

Autofeeder contactor drops out and: mains supply to/from invertor to elevator motor is cut off.

In addition to the action of the safety relay, signals are sent from the cover interlocks and the interlock override switch to the LSB. If the LSB detects an unsuitable condition it issues an error code on the MMI.

INTERLOCK BOX

I/LOCK SHUTTER (LASER ON/OFF)

I/LOCKS

+36V +24V

VOLUME 2 (6-14) P OWER AND C ONTROL M ODULES

PWR1

A1+ 23 51C F2A Y1 X1 CONTACTOR (SIE 3RT 1016-1BB42) PLUG IN SURGE SUPPRESSOR 3RT 1916-1BB00 S22 24 A1+ 21NC 5L3 3L2 1L1 52C F1B F2B F3B FUSE (1A) FUSE (1A) A222NC 6T3 4T2 2T1

13

F1A F3A

A2-

SAFETY RELAY (AES 1235)

FUSE (1A)

PWR2

S13

S21

S14

14

Figure 6.7 Interlock wiring - schematic view

+36V EODD LASER IL ENG 24V 24V FROM PSU 24V GND FROM PSU +24V

PWR3

+36GND +24GND

PWR_IN

EODD LASER ILR

ENG 24V GND

L UXEL P LATESETTER VOLUME 2 (6-15)

Safety Relay Monitor Operation (AES 1235)

The AES 1235 operates as an interlock system monitor with two independent safety circuits, each consisting of a microprocessor and a relay. All inputs to the module are monitored and controlled by the device. Its main features are: two enabling paths, both having normally open (NO) contacts in series operating voltage of 24 V (+15 %) short-circuit protection (FS1). All inputs to the relay are monitored by the processors; if one of the switch contacts monitoring the interlock sensor changes state, while the interlock remains closed, then both safety relay circuits are disabled. When an interlock sensor is opened the safety relay outputs are disabled. Two microprocessors check the state of the switch inputs to determine if: failure of the interlock switch to change state shorting or break across the switch cable circuit cabling failure of the safety relay contacts to change state failure of the internal module circuitry failure of one of the processors. If a fault is determined, the operation of the safety relay is blocked and the fault type is shown on a diagnostic LED. If all the tests are satisfactory, the safety relays are energised. While the relays are closed, external sensors and module internal components are continuously monitored. The safety relay also includes over-current protection for the two contacts. The output (Y1) is High when the relay contacts are open and the outputs are disabled.

Safety Relay - Using the LED Diagnostics

The safety relay uses LEDs to indicate a variety of switching conditions (see Table 6.1) and failures (see Table 6.2). The error indication is cleared once the cause of the fault has been rectified and after all the interlocked covers have been tested (opened/closed) by the safety relay.
Table 6.1 Safety relay LED switching states
Display Description

Green LED on Yellow LED flashing (0.5 Hz) Yellow LED flashing (2 Hz)

Interlock is closed Interlock is open Interlock closed but incorrect operation caused voltage drop or open feedback control loop.

Table 6.2 Safety relay LED failure states

Display (Orange) One pulse Failure Possible Causes

Switch

- Defective lead to switch - Defective sensor switch - Switch only partially activated

VOLUME 2 (6-16) P OWER AND C ONTROL M ODULES

Table 6.2 Safety relay LED failure states (Continued)

Four pulses Five pulses

Malfunction at relay inputs one or both relays not responding within monitoring range Relays do not operate when cover is opened Cross-monitoring failure

- Possibly high capacitive/inductive interference at sensor leads - Insufficient operating voltage - Defective relays - possible defective contacts - Failure in one channel - Data transfer interruption

Six pulses Seven pulses

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 normally 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.

6.4 RFI Box Modules

This section describes the main RFI assemblies and their interface connections with the platesetter system.

6.4.1 RFI Box Layout and Assemblies

See also Volume 2 Chapter 2-10 for views of the RFI box cable interconnections and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.

L UXEL P LATESETTER VOLUME 2 (6-17)

SENSOR DISTRIBUTION PCB ASSEMBLY

24V DISTRIBUTION PCB ASSEMBLY DC CABLE MAINS INLET (10A 250V) POWER FILTER PCB POWER FILTER PCB INTERFACE DONGLE (OLD PCB ONLY)

PSU

EODD PCB

DISK DRIVE

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

The RFI Box consists of the following modules. AC Mains (Input): see Section 6.3.3. PSU 1: see Section 6.5.1. Power Filter PCB: see Section 6.5.4. LSB Fan: see Section 6.5.2. Electro-Optic Deflector Driver (EODD) PCB: see Section 6.6.1. System PCB (LSB): see Section 6.6.2. Hard Disk Drive 1: see Section 6.6.3. An alert control relay is housed at the service side of the box, see Section 6.7.2 for a description of the circuit.

VOLUME 2 (6-18) P OWER AND C ONTROL M ODULES

6.4.1.1 RFI Box External I/O Connections

See Figure 6.9. External I/O connections from the RFI box are from a side panel accessed when the Engine service side cover is removed.
24V DISTRIBUTION PCB ASSEMBLY SENSOR DISTRIBUTION PCB ASSEMBLY POWER FHMB POWER VBOMB POWER PSU CONTROL (TO LSB) 24V INTERLOCKS EXTERNAL ALERT RELAY

MAINS INLET

SIGNAL RIP (SCSI)

MMI

CAN2 (FHMB1)

CAN1 (VBOMB) PLATE PROCESSOR DIAGNOSTICS (RS232) PSU CONTROL

RFI BOX

IMAGE EODD IMAGE (VBOMB) (VBOMB)

Figure 6.9 RFI Box external signal/power connections

L UXEL P LATESETTER VOLUME 2 (6-19)

6.5 RFI Box - DC Power Modules

This section describes the main RFI box modules

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 Volume 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.
PSU 1 +5V 0V 15V +24V FHMB +36V +15V +15V/-15V +5V +15V/-15V PL10 PL11 PL13 PL17 LSB

4 4 4 4

PSU 1: see Section 6.5.1. Fans: see Section 6.5.2. Fusing: see Section 6.5.3. Power Filter PCB: see Section 6.5.4.

+36V +5V

PL4 PL5 PWR FILTER

+24V

PL3

EODD

+24V

FAN 1 (PIN 2)

Figure 6.10 Cable: PSU (9970-0421) DC connections

VOLUME 2 (6-20) P OWER AND C ONTROL M ODULES

SLOT 1

SLOT 3

SLOT 4

SLOT 5

SLOT 6

-15V SENSE 0V 0V +36V WHITE/BROWN +5V RED 0V +24V WHITE/ ORANGE 0V +24V WHITE/ ORANGE 0V +15V YELLOW (+15V) VIOLET (-15V) 0V

Figure 6.11 PSU 1 - voltage outlets

6.5.2 Fan Assemblies

6.5.2.1 Fan Assembly
See Figure 6.8. Three fan assemblies, fitted on mounting brackets, provide a flow of cool air for the main modules: PSU fan: Extracts hot air away from the PSUs. Note that the two PSUs include built-in fans. LSB PCB fan: blows in cool air towards the LSB. Note that failure of the LSB fan is detected by the software to give an error code. Each fan has a detachable finger-guard which needs to be refitted on a replaced fan.

6.5.3 System Control Fusing

The main fuses fitted on the platesetter are: FHMB PCB:

Interlock box: 1 A antisurge (FS1-3) 3-off 0.5 A (24 V PSU)

LSB PCB: 2 A antisurge (FS1) - 97280005

Emergency stop PSU: 0.5 A, 250 V antisurge 20 mm

4 4 4 4 4 4

2 A antisurge (FS1-7 and FS9-15) - 97280005. 5A antisurge (FS8) - 97280004.

L UXEL P LATESETTER VOLUME 2 (6-21)

EODD

6.5.4 Power Filter PCB

6.5.4.1 Power Filter Assembly
This PCB forms part of the DC distribution system and includes inline inductors for filtering DC power to: FHMBs (1 to 4). Interlocks (+24 V). VBOMB power. The Power Filter PCB does not include LEDs, links or fuses.

Location
Mounted inside the RFI box at the back of the upper shelf, see Figure 6.8.

Connectors
See Figure 6.12. PL1: PL2: PL3: PL4: PL5: PL6: PL7: PL8: SK1: SK2: 8-way Molex to FHMB (via Interlock Box). 10-way Molex to VBOMB_PWR. 4-way Molex to interlocks. 10-way Molex to PSU 1. 6-way Molex to PSU 1. 6-way Molex to PSU 1. 3-way Molex to PSU 2. 14-way Molex to EODD. 15-way D-type to LSB. 26-way D-type to Interlock box.

Connector Pin Descriptions

See also Volume 2 Chapter 2-10 for views of the Power Filter cable interconnections and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.

4 4

2 A A/S (FS2 and 4) - 97280005. 5A A/S (FS1 and 3) - 97280004.

VOLUME 2 (6-22) P OWER AND C ONTROL M ODULES

PL1

PL4

PL2

PL5 PL6 TP1 SK1

TP4 PL7 TP3 TP2

PL8

PL3 SK2

Figure 6.12 Power Filter PCB - layout view

6.5.4.2 Power Filter PCB Operation

The function of the Power Filter PCB is to: Route interlock status signals to the LSB via the EODD. Provide inductive EMI filtering all the voltage lines. Distribute DC voltages (+24, Engine_24, +36, +15 -15) to the VBOMB and FHMBs (via the Interlock box).

L UXEL P LATESETTER VOLUME 2 (6-23)

6.6 RFI Box - Image Processing Modules

This section describes the following electronic modules housed in the RFI Box:. EODD (MK2): see Section 6.6.1. System PCB: see Section 6.6.2. Hard Disk Drives: see Section 6.6.3.

6.6.1 Electro-Optical Deflector Driver (EODD) PCB

6.6.1.1 EODD PCB Assembly
See Figure 6.13 showing the PCB layout.

TP13 PL9 TP20 TP14 TP12 TP17 PL10 FS3 TP11

TP8 PL6 TP3

TP9 TP10

TP6 FS2

FS1 PL2

PL3 TP15 FS4 TP7 PL14 SK4 TP18 PL13 SK2 TP19 PL8 TP2 TP1 PL4

TP16

SK1 PL11 SK3 TP5

TP4

PL5 PL12

Figure 6.13 EODD (MK2) PCB - layout view

VOLUME 2 (6-24) P OWER AND C ONTROL M ODULES

Location
Mounted inside the RFI box on the lefthand side, see Figure 6.8.

Connectors
PL1: PL2: PL3: PL4: PL5: PL6: PL8: PL9: PL10: PL11: PL12: PL13: PL14: SK1: SK2: SK3: SK4: Not Used. Not Used. 8-way Molex Minifit. PSU connection to PSU 1. 14-way Molex. Interlock sensor status routing to LSB. Not used. 6-way Molex. EOD (X) and EOD (Y) signals. Not used. Not used. Not used. Not used. Not used. Not used. Not used. D-type 37-way. EODD_IF connection to LSB. Not Used. Not Used. Not Used.

Connector Pin Descriptions

See also Volume 2 Chapter 2-10 for views of the EODD cable interconnections and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.

Fuses
FS1: FS2: FS3: FS4: 5 A anti-surge (97280004) 5 A anti-surge (97280005) 5 A anti-surge (97280004) - Spare 5 A anti-surge (97280005) - Spare.

LEDs and Links

None

Test Points
TP1: TP3: TP5: TP6: OV +24 V 0V +12 V

L UXEL P LATESETTER VOLUME 2 (6-25)

TP7: TP8: TP9: TP11:

+5 V Y-DEFL X-DEFL O V.

6.6.1.2 EODD PCB Operation

See Figure 6.14. The EODD provides a number of expose control functions: Generates the EOD DIFF sine/cosine waves used to deflect the beams. Serves as a control interface between the LSB DAC target settings and the EODs. Receives interlock status signals from each interlocked cover to control the laser and re-directs status signals to the LSB for interpretation.

CONTROL LSB PORT I/FACE

EOD X DAC

SINE WAVEFORM TO EODHV

EOD Y DAC

COSINE WAVEFORM TO EODHV

LSB

OK

POWER FILTER

6 PANEL I/LOCKS

PANEL I/LOCKS REGISTER

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

EOD DIFF Deflector

A 12-bit DAC and a DIFF driver provides a composite DC bias and AC modulation voltage for each EOD. These are passed to the EODHV module that filters the two components and provides the HT drive. The deflector wave outputs, at 500 Hz locked to the spinner rotation, are: EOD X is sine wave EOD Y is cosine wave. EOD sine and cosine data is derived from the deflector LUTs on the LSB which are addressed (updated) at a rate scaled to the spinner revolutions. Up to 2048 updates per spinner revolution are possible, depending on the resolution selected.

6.6.2 System Board (LSB) PCB

6.6.2.1 System PCB Assembly
See Figure 6.15 showing the PCB layout.

Location
Mounted in the RFI box at the rear of the Engine, see Figure 6.8.

Connectors
PL1: PL2: PL3: PL4: PL5: PL6: PL7: PL8: PL10: PL11: PL12: PL13: PL15: PL16: PL17: PL18: PL19: PL20: PL21: Not used. 50-way male vertical header. Data to/from local SCSI disk drive 2. 40-way male header. Used for dongle on old PCBs; not fitted on new PCBs. Not Used. Not Used. 4-way male vertical header. +12V and +5VDC DC supplies to SCSI disk drive1. Not Used. 4-way male vertical header. +12V and +5VDC supplies to SCSI disk drive2. 6-way DIL male header. +15V DC supply from PSU to on-board regulators supplying +12V to disk drive(s) 12-way DIL male PCB header. -15V, +15V from the PSU. Not Used. 14-way DIL male PCB header. +5V from the PSU. Not Used. Not Used. 10-way DIL male header. -15V, +15V from the PSU. Not Used. Not Used. 9-way male D-type. RIP serial diagnostics. 9-way male D-type. Processor serial connection to plate processor.

L UXEL P LATESETTER VOLUME 2 (6-27)

SK1: SK2: SK4: SK5: SK6: SK7: SK8: SK9:

37-way female D-type. Interface to EODD. Not Used. 26-way female D-type. Image VBOMB. 15-way female D-type. PSU Control. 15-way female D-type. CAN1 Bus to VBOMB. 15-way female D-type. CAN2 Bus to FHMB (1). 26-way female D-type. +5V and Data to/from MMI. 68-way female connector. SCSI bus to RIP server.

Connector Pin Descriptions

See also Volume 2 Chapter 2-10 for views of the LSB cable interconnections and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.

Fuses
FS1: (5V, 2A) - Anti-surge. SCSI Power Termination.

ICs (Main Devices)

U31 U36: U39: U51: U52: U53: U65: U66: U67: U69: U70: U76: U113: NVRAM. Real-time clock. 512 k x 8 bit SRAM. SRAM temporary data store for main program. 512 k x 8 bit SRAM. SRAM temporary data store for main program. 512 k x 8 bit FLASH memory. 512 k x 8 bit FLASH memory. 512 k x 8 bit FLASH memory. 512 k x 8 bit FLASH memory. 512 k x 8 bit FLASH memory. 512 k x 8 bit FLASH memory. Temperature Sensor. Monitors ambient temperature of System board. 512kx8 bit FLASH memory-plug-in. Contains program code for SRAM U76 and U113. Any change of code requires U70 to be exchanged. XC4020XL-2. Static RAM. XC4013XL-1. Static RAM.

U51-53 are FLASH memory which contain the System code (Boot, Diagnostics and Application). Any change of code required is downloadable. U65-67 are FLASH memory which contain the System code (Boot, Diagnostics and Application). Any change of code required is downloadable.

VOLUME 2 (6-28) P OWER AND C ONTROL M ODULES

PL11

PL13 U53 U67 U66

RL1

PL17 SK2

PL18

SK1

U52 U51

TP13 U65 TP4

D19

SK9

FS1 PL7 PL12 TP5

PL3 (DONGLE) TP3

TP15 TP12

SK8

SK7 TP14 PL2 LK6 LK7 U76 PL19 PL16 PL1 TP2 TP18 U70 U113 TP7 TP9 TP6 TP8 TP10 PL10 LK1 LK3 LK4 LK5 PL15 TP16 SK4 SK5 PL21 PL20 SK6

PL6 PL5 PL4

PL8

LK2

U69

Figure 6.15 System Board (LSB) layout

LEDs
D2: D3: D4: Red LED. Illuminated = System board in Reset. Green LED. For S/W purposes. Green LED. For S/W purposes.

Links
LK1: LK2: Not fitted. Pins 1 and 2 connected (on-board program enabled).

L UXEL P LATESETTER VOLUME 2 (6-29)

LK3: LK4: LK5: LK6: LK7:

Not fitted. Not fitted. Not fitted. Not fitted. RS232 Comms. interface to film processor. Link in if processor has no Flow Control. MAKE SURE THE LINK IS OUT.

Test Points
TP1: TP2: TP3: TP4: TP5: TP7: TP8: TP9: TP11: TP12: TP13: TP14: TP15: TP16: TP17: TP18: TP19: Digital Ground. Digital Ground. Digital Ground. Digital Ground. Reset. Digital Ground. Not used. Not used. Digital Gnd Digital Gnd. Not used. PLL_LOCKED Not used. Digital Ground. Digital Ground. TTL pixel clock (fast clock for image data output to VBOMB. ECL Ground.

6.6.2.2 Dongle
A Dongle PCB is stacked on the LSB PL3 header (see Figure 6.15) to enable the software for a dual-beam system.

6.6.3 Hard Disk Drives (HDD)

See Figure 6.8.

6.6.3.1 Disk Drive Assembly

A single SCSI disk drive has a data capacity of 18 Gbytes and is supported by a mounting bracket at the side of the RFI box. Its main functions are: Buffers single image compressed data before it is decompressed and sent to the optics system for laser modulation. Holds a copy of the NVRAM parameters used by the LSB. Backup copies of the Configuration files and System Registry. Local persistent images (PIs)

VOLUME 2 (6-30) P OWER AND C ONTROL M ODULES

Error Log files. Cassette and elevator databases. Local statistics on the system current usage.

SCSI Standard
The HDD is Narrow (8-bit) Ultra SCSI.

Disk Drive Settings

The HDD should be correctly configured by the manufacturer. Details of the configuration are labelled on the drive. The working SCSI ID can be any number from 0 to 6 (but not 7), but it is usually set to 0.

DC Supplies
+12 V 5% (regulated from the LSB) and +5 V.

Operating Temperature
5C to 55C.

Terminators
The HDD has its own controller which requires terminating using passive an inline cable terminator. You can leave the existing terminator in place when replacing the drive.

Disk Drive Cable Connections

See also Volume 2 Figure 9.3 for views of the HDD cable interconnections and Volume 2 Section 8.1 for a description of the cable pin voltages and signals.

6.7 MMI and External Alert

6.7.1 Man Machine Interface (MMI)
The MMI is a display console that operates the platesetter user controls from an iconic menu system. The console consists of an LCD, an analogue touchpanel, Invertor PCB and MMI PCB. These devices are assembled as a single FRU fitted inside a plastic console and held by a support moulding to the engine. A clear window with the display and touchpanel is presented to the user.

MMI PCB Assembly

See Figure 6.16.

L UXEL P LATESETTER VOLUME 2 (6-31)

SK1

SK2

U1 PL1

WD1 (BUZZER)

FS1 MMI PCB

SK3

SK4

Figure 6.16 MMI PCB layout

Location
Mounted inside the MMI Display console on the Engine.

MMI Connectors
PL1: SK1: SK2: SK3: SK4: 3-way. Supplies +5V, Ground and on/off control signal to Inverter board. 4-way. Signals from touchpanel. Not used. 14-way. Routes drive signals to the LCD. 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 Volume 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

SK1

SK2

WHITE

U1 PL1 INVERTER PCB WD1 (BUZZER) CAUTION HIGH VOLTAGE SK4 CN1

FS1 MMI PCB LCD AND TOUCHPANEL

SK3

TO PL1 (MMI PCB)

Figure 6.17 MMI console assemblies

The MMI includes: LCD display: with monochrome (emulating grey levels) for the MMI buttons and icons. The screen is specially adapted for daylight viewing, with a facility for the user to adjust the contrast. Inverter board: located next to the MMI board, powers a single fluorescent lamp for the LCD backlight. The LCD backlight is also used as the machine power-on indicator. CAUTION ON VOLTAGE: the inverter generates high voltage (300 VDC). Touchpanel: allows the operator to select soft menus buttons. This panel may require periodic calibration by the user. MMI board: includes the I/O connectors to the System Board and an audible buzzer to alert the user. Adjustments for frequency and loudness is possible from the panel. Support moulding: engine support for the MMI assemblies. A full description of how the platesetter operates from the MMI console is given in the

L UXEL P LATESETTER VOLUME 2 (6-33)

Luxel Platesetter Operator's Manual. MMI control and drive voltages are managed from the System Board to include: dedicated LCD display controller display memory (128 K DRAM) contrast control (negative voltage generator) for varying the LCD backlight buffer for LCD data/control signals +5V for the Inverter board and MMI PCB devices touchpanel supply voltage (+5 V) to X and Y touch panel axes A-to-D signals for X and Y positions beeper ON signal. A Diagnostics submenu runs a set of self-tests for the engineer and user.

6.7.2 External Alert Control

An external alert facility is fitted as a customer option using the circuit shown in Figure 6.18. The customer is responsible for supplying and fitting the remote alert device (light or buzzer) and an external DC PSU. The alert is initiated by the application software when an error is indicated (for instance, a plate jam or a lack of media for the next job). The control relay (BV8) is located on the RFI box, see Figure 6.9.

ENGINE EXTERNAL ALERT RELAY PIN 7 ALERT CONTROL FROM FHMB1 PIN 2 PIN 3 PIN 4 COIL A ALERT RELAY (ON RFI BOX) PIN 4 PIN 7 COIL B 9-WAY D-TYPE (FEMALE)

ENGINE EXTERNAL PLATE

REMOTE LIGHT OR AUDIBLE ALARM

UP TO 36V DC SUPPLY (24V TYPICAL) RATING LESS THAN 2A

Figure 6.18 Connecting an external alert

VOLUME 2 (6-34) P OWER AND C ONTROL M ODULES

Volume-Chapt er

VACUUM AND AIR CONTROL

This chapter describes drum vacuum/air blow system for plates in the drum, and the air knife and purified air system for controlling contaminants:

7.1 Vacuum and Contamination Control

Volume 2 Section 2.3 describes the sequence of steps for moving, de-skewing, conforming and ejecting a plate inside the drum. Figure 7.1 shows the vacuum/blow sub-system control for the drum and air knife/curtain.

7.1.1 Drum Vacuum and Drum Blow

This provides plate vacuum conformance and ejection inside the drum. The vacuum is sourced by an external pump with AC power switched from FHMB4 control to relay BV5; drum blow air is provided by internal compressors with AC power controlled by FHMB4 to relay BV31. Two types of vacuum/blow configurations are fitted on Violet machines:
A) B)

7.1.2 Contamination Control

This is provided by two separate functions:
1. Air Knife: switches on air at the Engine input to blow surface contaminants from the

4 4 4 4

Vacuum and Contamination Control ........................................................................ 7-1 Drum Vacuum and Drum Blow .................................................................................. 7-4 Air Knife..................................................................................................................... 7-18 Air Purifier (PAT) ....................................................................................................... 7-21

Old Drum Vacuum and Blow: applies to machine configurations up to 117. New Drum Vacuum and Blow: applies to machine configurations from 118.

plate as it advances into the drum. Air generated from the compressor box is switched by BV41. Air knife assemblies on early fully-automatic Violet machines use a fan blower located on the PTM to generate air movement. See Section 7.3.

MANIFOLDS NOT SHOWN CABLE: ENG_BLOW_AUTO_PUNCH NOTE: SEE FIGS. 3 TO 5 FOR EACH CAGE CONFIGURATION BV40 MAIN VAC

LEAD EDGE

VACUUM PUMP

CCT BREAKER PL10

FHMB1
BV30 SHORT BLOW

VOLUME 2 (7-2) VACUUM AND A IR C ONTROL

MAINS INLET PL1 PL10 PL8 PL16

BV5 RELAY

AIR KNIFE BV41 LONG BLOW

FHMB4 VALVE CAGE

FUSE L COMPRESSOR

BV31 RELAY

Figure 7.1 Vacuum/drum blow system control

L FUSE COMPRESSOR

INTERLOCK BOX

NOTE: SYSTEM SHOWN: B1 FULLY AUTO, SEMI, MANUAL (NO PUNCH)

MANIFOLDS NOT SHOWN

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.

7.1.2.1 Contamination Managementl

The contamination management system uses an inline air knife/air curtain to remove contaminants, such as:

The air knife/curtain assemblies are described in Volume 2 Section 3.4.2.2.

NOTE: To ensure contamination is reduced to the minimum, all scheduled service cleaning procedures, described in Section Volume 3 Section 1.5, must be followed.

The aim of contamination control is to:

1. Prevent debris settling on any flat surfaces inside the platesetter where there is a risk

2. Ensure plates are clean before a drum load. 3. Isolate system cooling fans from the drum interior. 4. Form effective seals on machine covers to prevent entry of debris. 5. Ensure there are no contaminants on the emulsion side of the plate. 6. Provide positive air pressure inside the Engine. 7. Provide a clean environment inside the optics base.

4 4 4 4 4

aluminium shards from the plates (cut edges) external dust PVA debris paper debris scrapings from painted surfaces, rollers, etc.

of transfer to the drum caused by circulating fan air.

VOLUME 2 (7-4) VACUUM AND A IR C ONTROL

7.2 Drum Vacuum and Drum Blow

Drum vacuum is required for conforming plates to the drum before exposure to ensure quality imaging. Drum blow control is applied:
A) B)

Before imaging to provide a bed a of air for the plate as it enters the drum After imaging to release the plate quickly from drum vacuum and assist ejection to the output transport.

Drum vacuum and drum blow is controlled by sequencing software during the plate load, plate conform, plate expose and plate eject stages. The plate handling sequence for each variant is described in Volume 2 Section 2.3.

7.2.1 Drum Configurations

7.2.1.1 Drum with Manifolds
See Figure 7.2. This section describes the drum blow configurations used for machine IDs 118 and onwards (New) and their differences with the pre-118 (Old) drum configurations: Old - ID 1 to ID 64 - these operate with 11 activated blow holes Old - ID 65 to ID 117 - these have 9 activated blow holes and a second manifold for additional 7 blow holes which are plugged, but capable of being upgraded in the field. New - ID 118 onwards - these have 9 and 7 activated blow holes described below. The new drum vacuum/blow system is designed to improve the throughput of large plates (greater than 350 mm) and small plates (less than 350 mm). Sets of drum holes, starting from the drum input end, are arranged around the outside of the New drum as follows:
1. 2. 3.

Long Blow (LB): a set of 9 holes used to release the plate. Note that the two end holes are plugged. Short Blow (SB): an additional set of 7 holes added to the new drum. It operates at the same time as LB but provides extra lift to prevent plate scratching. Main Vacuum (MV): a set of 23 holes provide the main conform vacuum after the plate has been de-skewed. Drum blow is applied to release the vacuum and plate after imaging. Lead Edge (LE): a set of 23 holes that operate on non-punch machines (Web) to vacuum and secure the leading edge of the plate, and prevent it from skewing when applying vacuum to the rest of the plate.

4.

L UXEL P LATESETTER VOLUME 2 (7-5)

EXTERNAL VACUUM PUMP

LEAD EDGE VALVE CAGE

MAIN VAC

BRANCH ELBOW MANIFOLD

BRANCH ELBOW

SHORT BLOW

LONG BLOW

VIEW FROM BELOW

Figure 7.2 Drum holes and manifolds (new drum with manifolds)

7.2.1.2 Drum with Chambers

See Figure 7.3. Later machines have a revised drum design with direct pipe connections between the valve cage and the four drum inlets for the lead edge, main vac, short blow and long blow. This design replaces the network of branching manifolds with a network of chambers inside the drum. As part of the servicing routine, check the vacuum/air seals of the drum pipe inlets located under the drum and at the output end between the optical base and RFI box.

VOLUME 2 (7-6) VACUUM AND A IR C ONTROL

EXTERNAL VACUUM PUMP

DIRECT FROM PUMP ON SOME CONFIGS

VALVE CAGE

LEAD EDGE

MAIN VAC

OPTICS BASE

RFI BOX

SHORT BLOW

LONG BLOW

VIEW FROM BELOW

Figure 7.3 Drum holes and manifolds (new drum with chambers)

7.2.2 Drum Vacuum and Blow Assemblies

See Figure 7.2. The main vacuum and blow assemblies are as follows:
1. 2.

External vacuum pump: a Becker VT 4.25 pump powered from the 230 VAC Engine supply. The pump requires periodic servicing described in the OEM service manual. Solenoids, manifolds, tubing and drum: vacuum tubing from a branch system of

L UXEL P LATESETTER VOLUME 2 (7-7)

manifolds and solenoids distribute vacuum/air to a drum with the new configurations 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.

7.2.3 Drum Vacuum and Blow System

Old and New configurations are available for the following platesetter machines:
1. B1 Fully-Automatic and Manual (without a punch): see Section 7.2.3.1.
A) B) C)

Old 1: see Figure 7-7.4. Old 2: see Figure 7-7.5 and Table 7.1. New 1: see Figure 7-7.6 and Table 7.2. Old 1: see Figure 7.7 and Table 7.3. New 1: see Figure 7.8 and Table 7.4. New 2: see Figure 7.9 and Table 7.5. Old 1: see Figure 7.10 and Table 7.6. New 1: see Figure 7.11 and Table 7.7.

2. B1 Fully-Automatic (with a punch): see Section 7.2.3.2.

A) B) C)

3. B2 Manual and Semi-Automatic (without a punch): see Section 7.2.3.3.

A) B)

VOLUME 2 (7-8) VACUUM AND A IR C ONTROL

7.2.3.1 B1 Fully-Auto and Manual (without a Punch)

BV40 VAC PUMP INPUT LE

P BV5 R BV30 A BLOW MANIFOLD MAIN VAC

COMPRESSORS (x 2) R A BV31 VALVE CAGE BV41 P AIR KNIFE

MANIFOLD

(P = PRESSURE; R = RETURN) P A COMPRESSOR BLOW NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE P VAC PUMP A LEAD EDGE R BV40 P VAC PUMP COMPRESSOR R BV30 A MAIN VAC R BV41 AIR KNIFE

Figure 7.4 B1 Fully-Auto and Manual without punch - vacuum circuit (Old 1)

L UXEL P LATESETTER VOLUME 2 (7-9)

BV40 INPUT LE

VAC PUMP

P BV5 R BV30 A BLOW MANIFOLD MAIN VAC

COMPRESSORS (x 2) P A BV31 VALVE CAGE BV41 R AIR KNIFE

MANIFOLD

(P = PRESSURE; R = RETURN) P A COMPRESSOR BLOW NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE P VAC PUMP A LEAD EDGE R BV40 P VAC PUMP A BLOW R BV30 R BV41 AIR KNIFE

Figure 7.5 B1 Fully-Auto and Manual without punch - vacuum circuit (Old 2)

VOLUME 2 (7-10) VACUUM AND A IR C ONTROL

VAC PUMP LE

INPUT

P BV5 R BV40 A MAIN VAC LONG BLOW

SHORT BLOW

P R BV30 A

MANIFOLD

COMPRESSORS (x 2) P A BV31 VALVE CAGE BV41 R

MANIFOLD

AIR KNIFE

(P = PRESSURE; R = RETURN) P A COMPRESSOR AIR KNIFE NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE P LE & VAC COMPRESSOR R BV40 P MAIN VAC (BV40) COMPRESSOR R BV30 A SHORT BLOW A MAIN VAC AND BV30 (P) R BV41 LONG BLOW

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 1 0 1 1 1 0 1 0 0 0 1 0 1 1 0 Eject Blow 0 1 0>>1 0 1 Main Vac 1 0 1 0 0 1 0 0 0 0 Main Vac Function Solenoid Air Knife Neutral

BV5 BV31 BV40 BV30 BV41

Vac Pump Compressor LE Valve Vac Divert Valve Blow Divert Valve

0 0 0 0 0

0 1 0 1 1

0 1 0 0 1

Table 7.2 Solenoid logic table for B1 fully-auto and manual - no punch (New 1) Short Blow Long Blow Function Solenoid Air Knife

Neutral

BV5 BV31 BV40 BV30 BV41

Vac Pump Compressor LE Valve Vac Divert Valve Blow Divert Valve

0 0 0 0 0

0 1 1 1 0

0 1 1 0 1

0 1 0 0 1

LE Vac

LE Vac

Blow

VOLUME 2 (7-12) VACUUM AND A IR C ONTROL

7.2.3.2 B1 Fully-Auto (with a Punch)

INPUT

VAC PUMP P R BLOW MANIFOLD BV30 MAIN VAC

BV5

AIR KNIFE

A COMPRESSORS (x 2) BV41 VALVE CAGE BV31

P R

MANIFOLD

(P = PRESSURE; R = RETURN) P A COMPRESSOR BLOW R BV41 AIR KNIFE

NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE

BV30 P VAC PUMP COMPRESSOR R A MAIN VAC

Figure 7.7 B1 Fully-Auto with punch - vacuum circuit (Old 1)

L UXEL P LATESETTER VOLUME 2 (7-13)

INPUT

VAC PUMP MANIFOLD MAIN VAC SHORT BLOW LONG BLOW

MANIFOLD P A BV41 P COMPRESSORS (x 2) R PLUG VALVE CAGE BV31 (P = PRESSURE; R = RETURN) P A COMPRESSOR AIR KNIFE R BV41 SHORT BLOW BV30 A R

AIR KNIFE

MANIFOLD

NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE

BV30 P COMPRESSOR PLUG R A LONG BLOW

Figure 7.8 B1 Fully-Auto with punch - vacuum circuit (New 1)

VOLUME 2 (7-14) VACUUM AND A IR C ONTROL

INPUT

VAC PUMP MANIFOLD MAIN VAC A BV41 R P A BV41 P COMPRESSORS (x 2) R PLUG VALVE CAGE BV31 (P = PRESSURE; R = RETURN) P A COMPRESSOR AIR KNIFE R BV41 R SHORT BLOW NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE A SHORT BLOW BV30 A R SHORT BLOW LONG BLOW

BV5

MANIFOLD

AIR KNIFE

MANIFOLD

P BV40 P

COMPRESSOR PLUG R BV30

A LONG BLOW

Figure 7.9 B1 Fully-Auto with punch - vacuum circuit (New 2)

L UXEL P LATESETTER VOLUME 2 (7-15)

Table 7.3 Solenoid logic table for B1 fully-auto - with punch (Old 1) Eject Blow 1 0 1 1 0 1 0 0 1 0 0 0 Eject Blow 0 1 1 1 1 0 0 0 Eject Blow 0 1 1 1 Main Vac 0 1 1 0 0 1 1 1 0 1 1 1 Main Vac Main Vac Function Solenoid Air Knife Neutral

BV5 BV31 BV30 BV41

Vac Pump Compressor Vac Divert Valve Blow Divert Valve

0 0 0 0

0 1 1 1

Table 7.4 Solenoid logic table for B1 fully-auto - with punch (New 1) Long Blow 0 1 0 0 0 1 0 0 Long Blow Function Solenoid Air Knife Neutral

BV5 BV31 BV30 BV41

Vac Pump Compressor Vac Divert Valve Blow Divert Valve

0 0 0 0

Table 7.5 Solenoid logic table for B1 fully-auto - with punch (New 2) Solenoid Function Air Knife Neutral

BV5 BV31 BV30 BV41 BV40

Vac Pump Compressor Vac Divert Valve Blow Divert Valve Extra Vac Valve

0 0 0 0

Activated with BV41

Blow

VOLUME 2 (7-16) VACUUM AND A IR C ONTROL

7.2.3.3 B2 Semi-Auto and Manual (without a Punch)

INPUT VAC PUMP MANIFOLD LE

P PLUG BV5 R

A BV30 MANIFOLD MAIN VAC

LONG BLOW

COMPRESSORS (x 2) P A BV41 BV31 VALVE CAGE R

AIR KNIFE

MANIFOLD

(P = PRESSURE; R = RETURN) P A COMPRESSOR MAIN VAC R BV41 AIR KNIFE

NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE

BV30 P VAC/LE PLUG R A MAIN VAC/SHORT BLOW

Figure 7.10 B2 Semi-auto and Manual without punch - vacuum circuit (Old 1)

L UXEL P LATESETTER VOLUME 2 (7-17)

INPUT VAC PUMP MANIFOLD LE

P PLUG R

A BV30 MANIFOLD MAIN VAC SHORT BLOW

LONG BLOW

COMPRESSORS (x 2) P A BV41 BV31 VALVE CAGE R

AIR KNIFE

MANIFOLD

(P = PRESSURE; R = RETURN) P A COMPRESSOR MAIN VAC/SHORT BLOW R BV41 AIR KNIFE

NOTE: RETURN IS NEAREST TO VALVE CAGE PLATE

BV30 P VAC/LE PLUG R A MAIN VAC/SHORT BLOW

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 1 0 1 1 0 1 0 0 1 0 1 1 Eject Blow 0 1 0 0 Main Vac 1 0 0 0 Main Vac 0 1 0 0 LE Vac 0 1 0 0 Function Solenoid Air Knife Neutral

BV5 BV31 BV30 BV41

Vac Pump Compressor Vac Divert Valve Blow Divert Valve

0 0 0 0

0 1 1 1

Table 7.7 Solenoid logic table B2 semi-auto and manual without punch (New 1) Long Blow 0 1 1 1 Solenoid Function Air Knife Neutral

BV5 BV31 BV30 BV41

Vac Pump Compressor Vac Divert Valve Blow Divert Valve

0 0 0 0

7.3 Air Knife

7.3.1 Air Knife (Compressor)
NOTE: the compressor version is fitted on later production machines.

See Figure 7.12 and Volume 2 Figure 3.56. The air knife, located before the input transport module, blows clean air across an advancing plate before it reaches the drum. This removes surface debris from the plate before there is a transfer of contaminants to the drum. The air knife system consists of the following assemblies:
1. 2.

Air knife pipe: this pipe, located above the input module, directs small streams of air down to the plate and towards the plate feed area. BV41: this solenoid, located on the valve cage, controls the flow of compressed air from the compressor box to the air knife as a plate passes underneath.

Blow

L UXEL P LATESETTER VOLUME 2 (7-19)

PLATE ADVANCING FROM AUTOFEEDER

AIR KNIFE/CURTAIN PIPE

DUCTING PIPE

BV41

VALVE CAGE AND PLATE

Figure 7.12 Air knife contamination control (compressor)

7.3.2 Air Knife (Fan Blower)

NOTE: the fan blower version is fitted on early production machiones.

See Figure 7.13 and Volume 2 Figure 9.8. The air knife, located before the input transport module, blows clean air across an advancing plate before it reaches the drum. This removes surface debris from the plate before there is a transfer of contaminants to the drum. The air knife system consists of the following assemblies:
1. Fan blower: an AV-mounted fan blows air into the pipe duct as the plate

advances from the feed head. plate advances.

2. 24 VDC relay: switches the +24 V supply on/off (from FHMB3 control) as the 3. Air knife pipe: this pipe, located above the input module, directs small

streams of air down to the plate and towards the Autofeeder.

VOLUME 2 (7-20) VACUUM AND A IR C ONTROL

AIR KNIFE PIPE

PLATE ADVANCING FROM AUTOFEEDER

DUCTING PIPE

AV MOUNTS

OUTLET DUCT

CONTROL RELAY (BV23) FAN BLOWER AND HOUSING

PTM INTERIOR (SERVICE SIDE)

Figure 7.13 Air knife contamination control (fan blower)

7.3.3 Servicing the Air Knife

7.3.3.1 Fan Blower
1. Detach the ducting pipe above the housing. 2. Disconnect the fan from the relay (inline connector). 3. Remove the fan housing from the frame (4-off M5 nuts). 4. Remove and replace the fan blower assembly from its housing. 5. Replace the assembly and reconnect. 6. Check that the fan operates correctly when the plate starts to move towards the
input module.

L UXEL P LATESETTER VOLUME 2 (7-21)

7.3.3.2 Control Relay (BV23)

1. Detach the relay from the frame. 2. Disconnect the relay wires shown in Figure 7.14. 3. Replace and reconnect the relay. 4. Check that the fan operates correctly when the plate starts to move towards the
input module.

FHMB3 (PL1)

9970-0198

+24V PTM CONNECTOR PANEL 9970-0156 0V 0V +24V AIR KNIFE FAN

A
FRONT

BV23 RELAY

Figure 7.14 Air knife control circuit

7.4 Air Purifier (PAT)

The PAT-506id operates as a separate module supplying highly purified air to the drum from a flexible ducting connection to a manifold on the Engine cover (service side). Clean air from the Engine is also drawn into the optics base by a laser cooling fan. Purified airflow reduces contamination and thereby improves performance by reducing time spent cleaning the spinner mirror and checking for image quality.
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

7.4.1 Servicing the PAT

Clean air on the PAT is supplied via three (staged) filters which need to be replaced when a warning beep/LED flashing occurs. Although this warning indicates that the filters are due for replacement, customers can still operate the machine for a recommended short period. Servicing the PAT depends on the local arrangement between the customer and the PAT distributor. FFEI (UK) are able to provide more information on local PAT servicing and parts supply.
CAUTION: Failure to replace filters as recommended could result in lower optics efficiency 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. 2. 3.

Green: the purifier is operating normally. Yellow: specific filters have two weeks before their scheduled replacement 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 disabled. 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.

7.4.2 Service Filtering for the Optics Base

Before accessing the optics base interior, purified air from the PAT is diverted to the base using the service manifold tool (Part No 7A04975). A flow of clean air from the ducting prevents contamination while the optics modules are exposed.

1. Switch off the platesetter and the PAT. 2. Loosen the PAT filter hose from the Engine door manifold and move the PAT to the
optics base.

3. Remove the optics base cover panel and fix the service manifold as shown in
Figure 7.15. Attach the duct to the service tool and switch on the PAT.

L UXEL P LATESETTER VOLUME 2 (7-23)

OPTICS BASE

SERVICE MANIFOLD

DUCTING

TO PAT

Figure 7.15 Fitting the service manifold

VOLUME 2 (7-24) VACUUM AND A IR C ONTROL

Volume-Chapt er

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.

8.1 Cable Pin Descriptions

8.1.1 I/LOCKS_MAINS (9970-0119)
Label 0.25 FASTON FUSE" BROWN 200 mm 0.25" FASTON Label REL 9"

Cable Pin Descriptions .............................................................................................. 8-1

M4 FORKS 70 mm BLUE BROWN Label C/B IN" 270 mm 70 mm

M5 FORKS Label Label 3R 5L3" 3R 1L1" BLUE BROWN

45 mm BLUE BROWN Label 0.25" FASTONS 40 mm Label Label REL 4" REL 6" BLUE BROWN 0.25" FASTONS Label LID" 140 mm M5 RINGS GREEN/YELLOW Label 150 mm C/B OUT" 150 mm

45 mm

BLADES Label Label NEUTRAL FEED" LIVE FEED" BLUE BROWN

40 mm

BLADES Label Label NEUTRAL" LIVE" BLUE BROWN

BOX" M5 RINGS

VOLUME 2 (8-2) S YSTEM C ABLING DESCRIPTIONS

8.1.2 MAINS_RFI_IN (9970-0122)

Tie wraps 200 mm 110 mm 30 mm Label LIVE DIST" Brown Blue Label NEUT DIST" Label RFI BOX" Label Part No. 120 mm GREEN/YELLOW Label CHASSIS"

8.1.3 DISK_PWR (9970-0129)

Table 8.1 Disk_PWR
AMP 1-480424-0 (4W) SSB PL 8 PIN 1 SSB PL 8 PIN 2 SSB PL 8 PIN 3 SSB PL 8 PIN 4 SSB PL 9 PIN 1 SSB PL 9 PIN 2 SSB PL 9 PIN 3 SSB PL 9 PIN 4 SIGNALS +12V GND DGND +5V +12V GND DGND +5V AMP 1-480424-0 (4W) DISK LEFT PIN 1 DISK LEFT PIN 2 DISK LEFT PIN 3 DISK LEFT PIN 4 DISK RIGHT PIN 1 DISK RIGHT PIN 2 DISK RIGHT PIN 3 DISK RIGHT PIN 4 WIRE COLOUR ORANGE GREY BLACK RED ORANGE GREY BLACK RED

80 mm Label SSB PL8 400 mm

80 mm Label DISK LEFT

Label SSB PL6 Equates to pin 1

Label DISK RIGHT

8.1.4 EOD (9970-0135)

Table 8.2 EOD
MOLEX MINIFIT JR SERIES (10W) EODD PL6 PIN 1 PIN 2 SIGNALS MOLEX MINIFIT JR SERIES (10W) EODHV BD PL9 PIN 1 PIN 7 TWIST WITH PL6 PIN 7 TWIST WITH PL6 PIN 8 ORANGE WHITE/ ORANGE YELLOW 18 AWG 18 AWG WIRE COLOUR COMMENTS

NOT USED EODX_SIGNA L EODY_SIGNA L +12V +24V

PIN 3

PIN 8

PIN 4 PIN 5

PIN 4 PIN 5

PIN 6 PIN 7

HV_BD_OK~ EODX_RTN

PIN 6 PIN 2

26 AWG 26 AWG

L UXEL P LATESETTER VOLUME 2 (8-3)

Table 8.2 EOD

PIN 8 PIN 9 PIN 10 EODY_RTN NOT USED GND (+24V) PIN 3 PIN 9 PIN 10 BLACK 18 AWG 26 AWG

Label EODHV BD PL9

Label EODD PL6

Label Pin 1

Label Pin 1

600 mm

8.1.5 CAN2 (9970-0138)

Table 8.3 CAN2
15 D TYPE PLG PIN 1 PIN2 SIGNAL 15 D TYPE PLG COLOUR COMMENTS

CHASSIS GND CAN GND

PIN 1 PIN2 BLACK / RED BLACK / WHITE

CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 3

CAN +5V

PIN 3

RED / BLACK WHITE / BLACK

PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11

CAN CAN + RESET RESET + INDEXINDEX + NO CONNECTION E_CLK-

PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11

BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK

(TWISTED PAIR WITH PIN 5)

(TWISTED PAIR WITH PIN 7)

(TWISTED PAIR WITH PIN 9)

( BLACK / BLUE (TWISTED PAIR WITH PIN 12)

Label SSB CAN SOMB pin 1

Label SOMB SK3 pin 1

1550 mm

VOLUME 2 (8-4) S YSTEM C ABLING DESCRIPTIONS

8.1.6 MMI (9970-0139)

Table 8.4 MMI
26 W PLG PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 SIGNALS SCREEN DATA_0 DATA_1 DATA_2 DATA_3 +5V XL XR CP+ GROUND GROUND GROUND GROUND LAMP_ON +5V YU YD CPLOAD GROUND FRAME_STA RT DIS PLAY_ON BUZZER +5V VADJ VEE 26 W PLG I PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 TWISTED PAIR WITH PIN 26 TWISTED PAIR WITH PIN 22 TWISTED PAIR WITH PIN 20 TWISTED PAIR WITH PIN 17 TWISTED PAIR WITH PIN 23 TWISTED PAIR WITH PIN 18 TWISTED PAIR WITH PIN 10 TWISTED PAIR WITH PIN 11 TWISTED PAIR WITH PIN 12 TWISTED PAIR WITH PIN 13 TWISTED PAIR WITH PIN 15 TWISTED PAIR WITH PIN 8 COMMENTS

Label m m i pin 1

Ferrites

Label SSB M M I pin 1

50 m m approx 4.2 m etres

50m m approx

L UXEL P LATESETTER VOLUME 2 (8-5)

8.1.7 INT_S41/S42 (9970-0140)

Table 8.5 INT_S41/S42
AMP CT PL4 PIN 1 PL4 PIN 2 PL4 PIN 3 PL4 PIN 4 PL2 PIN 1 PL2 PIN 2 PL2 PIN 3 PL2 PIN 4 SIGNALS NOT USED CASS FWD LIMIT SUPPLY CASS FWD LIMIT GROUND CASS FWD LIMIT SIGNAL NOT USED CASS REV LIMIT SUPPLY CASS REV LIMIT GROUND CASS REV LIMIT SIGNAL S42 PIN 1 S42 PIN 2 S42 PIN 3 TWISTED PAIR WITH S41 PIN 2 S41 PIN 1 S41 PIN 2 S41 PIN 3 TWISTED PAIR WITH S41 PIN 2 AMP EI

Label CASS ID PL4 Label S41

900 mm 30 mm Label CASS ID PL2 Label S42 50 mm

8.1.8 ENG_INT (9970-0142)

Label 0.25 FASTON FUSE" BROWN 200 mm 0.25" FASTON Label REL 9"

M4 FORKS 70 mm BLUE BROWN Label C/B IN" 270 mm 70 mm

M5 FORKS Label Label 3R 5L3" 3R 1L1" BLUE BROWN

45 mm BLUE BROWN Label 0.25" FASTONS 40 mm Label Label REL 4" REL 6" BLUE BROWN 0.25" FASTONS Label LID" 140 mm M5 RINGS GREEN/YELLOW Label 150 mm C/B OUT" 150 mm

45 mm

BLADES Label Label NEUTRAL FEED" LIVE FEED" BLUE BROWN

40 mm

BLADES Label Label NEUTRAL" LIVE" BLUE BROWN

BOX" M5 RINGS

Table 8.6 Eng_Int connector destinations

CONNECTOR A DESTINATION ENGINE O/P COVER INTERLOCK SENSOR EXTERNAL INTERLOCK INTERLOCK OVERRIDE KEYSWITCH LOCKS

B C

VOLUME 2 (8-6) S YSTEM C ABLING DESCRIPTIONS

Table 8.6 Eng_Int connector destinations

E F INT_SYSTEM ENGINE I/P COVER INTERLOCK SENSOR ENGINE SERVICE COVER INTERLOCK SENSOR PTM COVER INTERLOCK SENSOR ENGINE USER DOOR INTERLOCK COVER BUFFER COVER INTERLOCK SENSOR

H I

Table 8.7 ENG_INT

SIGNAL J PIN 2 A PIN 2 I PIN 2 G PIN 2 F PIN 2 H PIN 2 B PIN 4 J PIN 6 A PIN 6 I PIN6 G PIN 6 F PIN 6 H PIN 6 B PIN 9 J PIN 4 A PIN 4 I PIN4 G PIN 4 F PIN 4 E PIN 8 E PIN 9 E PIN 10 E PIN 11 E PIN 12 E PIN 13 H PIN 3 J PIN 7 B PIN 7 NO LOOP INTO I/LOCKS NO LOOP INTO I/LOCKS NO LOOP INTO I/LOCKS NO LOOP INTO I/LOCKS NO LOOP INTO I/LOCKS NO LOOP INTO I/LOCKS NO LOOP INTO I/LOCKS NO LOOP OUT FROM I/LOCKS NO LOOP OUT FROM I/LOCKS NO LOOP OUT FROM I/LOCKS NO LOOP OUT FROM I/LOCKS NO LOOP OUT FROM I/LOCKS NO LOOP OUT FROM I/LOCKS NO LOOP OUT FROM I/LOCKS S/W COMMON BRIDGE TO O/P COVER S/W COMMON O/P COVER TO CUST DOOR S/W COMMON CUST DOOR TO SERV DOOR S/W COMMON SERV DOOR TO I/P COVER S/W COMMON I/P COVER TO PANEL S/W COMMON IL1R-F TO IL2R_F S/W COMMON IL2R-F TO IL3R_F S/W COMMON IL3R-F TO IL4R_F S/W COMMON IL4R-F TO IL5R_F S/W COMMON IL5R-F TO IL6R_F S/W COMMON IL6R-F TO IL7R_F NC LOOP FUSED NC LOOP BRIDGE NC LOOP AES S22 A PIN 2 I PIN 2 G PIN 2 F PIN 2 H PIN 2 B PIN 4 C TINNED END LABEL PIN 1 A PIN 6 I PIN 6 G PIN 6 F PIN 6 H PIN 6 B PIN 9 D PIN 2 A PIN 4 I PIN 4 G PIN 4 F PIN 4 H PIN 4 E PIN 9 E PIN 10 E PIN 11 E PIN 12 E PIN 13 E PIN 14 D PIN 6 B PIN 2 D PIN 3

L UXEL P LATESETTER VOLUME 2 (8-7)

Table 8.7 ENG_INT (Continued)

D PIN 3 J PIN 3 A PIN 3 I PIN 3 G PIN 3 F PIN 3 D PIN 7 H PIN 9 H PIN 10 J PIN 8 A PIN 8 I PIN 8 G PIN 8 F PIN 8 H PIN 8 J PIN 4 H PIN 3 NC LOOP KEYSWITCH NC LOOP BRIDGE TO O/P COVER NC LOOPO/P COVER TO CUST DOOR NC LOOP CUST DOOR TO SERV DOOR NC LOOP SERV DOOR TO I/P COVER NC LOOP I/P COVER TO PANEL NO LOOP AES S14 CONTACTOR F CONTACTOR R S/W FEEDBACK 1L1_F S/W FEEDBACK 1L2_F S/W FEEDBACK 1L3_F S/W FEEDBACK 1L4_F S/W FEEDBACK 1L5_F S/W FEEDBACK 1L6_F S/W COMMON NC LOOP FUSED C PIN 4 A PIN 7 I PIN 7 G PIN 7 F PIN 7 H PIN 7 C PIN 2 D PIN 4 D PIN 8 E PIN 1 E PIN 2 E PIN 3 E PIN 4 E PIN 5 E PIN 6 E PIN 8 C PIN 3

8.1.9 INT_STAT (9970-0143)

Table 8.8 INT_STAT
PL 4 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 CN6 PIN 1 L_INTERLOCK NOT USED NOT USED SIGNALS INTERLOCK _P1 INTERLOCK _P2 INTERLOCK _P3 INTERLOCK _P4 INTERLOCK _P5 INTERLOCK _P6 INTERLOCK _P7 INT_RET_P1 INT_RET_P2 INT_RET_P3 INT_RET_P4 INT_RET_P5 INT_RET_P6 INT_RET_P7 PL 8 PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PL 3 PIN 1 PIN 2 PIN 3 TWIST WITH PIN 4 COMMENTS TWIST WITH PIN 8 TWIST WITH PIN 9 TWIST WITH PIN 10 TWIST WITH PIN 11 TWIST WITH PIN 12 TWIST WITH PIN 13 TWIST WITH PIN 14

VOLUME 2 (8-8) S YSTEM C ABLING DESCRIPTIONS

Table 8.8 INT_STAT

PIN 2 LASER5V PIN 4

8.1.10 CAN5_ENG (9970-0145)

Table 8.9 CAN5_ENG
15 D TYPE PLG SIGNAL 15 D TYPE PLG PIN 1 PIN2 BLACK / RED BLACK / WHITE PIN 3 CAN +5V PIN 3 RED / BLACK WHITE / BLACK PIN 4 PIN 5 PIN 6 CAN CAN + RESET PIN 4 PIN 5 PIN 6 BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK (TWISTED PAIR WITH PIN 9) (TWISTED PAIR WITH PIN 7) (TWISTED PAIR WITH PIN 5) COLOUR COMMENTS

PIN 1 PIN2

CHASSIS GND CAN GND

CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 7

RESET +

PIN 7

PIN 8

INDEX-

PIN 8

PIN 9

INDEX +

PIN 9

PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15

NO CONNECTION E_CLKE_CLK+ 0V CAN_SIG_RTN NO CONNECTION

PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 BLACK / BLUE BLUE / BLACK BLACK / BROWN BROWN / BLACK (TWISTED PAIR WITH PIN 14) (TWISTED PAIR WITH PIN 12)

8.1.11 ENG_FHMBPWR (9970-0146)

Label FHMB 1 PL31 Label I/LOCK BOX PWR 1 100 mm pin 1 120 mm 1100 mm Label I/LOCK BOX PWR 3 pin 1 250 mm Label I/LOCK BOX EMERG pin 1 220 mm Label PTM PANEL EMERG pin 1 Label PTM PANEL PWR 230 mm pin 1 pin 1

L UXEL P LATESETTER VOLUME 2 (8-9)

Table 8.10 ENG_FHMBPWR

MOLEX (10W) I/ LOCK BOX PWR 1 PIN 1 PIN 2 PIN 7 SIGNAL MOLEX (8W) FHMB1 PL31 CHASSIS GND +24V 24V GROUND PL31 PIN 1 PL31 PIN 2 PL31 PIN 6 BLACK WHITE/ORANGE BLACK SCREEN TWIST FHMB PL31 PIN 6 WIRE COLOUR COMMENTS

Table 8.11 ENG_FHMBPWR

MOLEX (10W) I/ LOCK BOX PWR 3 SIGNAL MOLEX (8W) PTM PANEL PWR CHASSIS GND +24V +24V PIN 1 PIN 2 PIN 3 BLACK WHITE/ORANGE WHITE/ORANGE SCREEN TWIST PTM PANEL PWR PIN 6 TWIST PTM PANEL PWR PIN 7 WIRE COLOUR COMMENTS

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10

24V GROUND 24V GROUND

PIN 6 PIN 7

BLACK BLACK

Table 8.12 ENG_FHMBPWR

MOLEX (6W) I/LOCK BOX EMERG PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 24V GND EMERG CHASSIS GND +24V EMERG SIGNAL MOLEX (6W) PTM PANEL EMERG PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 BLACK BLACK WHITE/ORANGE SCREEN TWIST WITH PIN 5 WIRE COLOUR COMMENTS

Table 8.13 ENG_FHMBPWR

MOLEX (10W) I/ LOCK BOX PWR 1 PIN 1 PIN 2 PINS 3 TO 6 PIN 7 PINS 8 TO 10 24V GROUND PL31 PIN 6 BLACK SIGNAL MOLEX (8W) FHMB1 PL31 CHASSIS GND +24V PL31 PIN 1 PL31 PIN 2 BLACK WHITE/ORANGE SCREEN TWIST FHMB PL31 PIN 6 WIRE COLOUR COMMENTS

VOLUME 2 (8-10) S YSTEM C ABLING DESCRIPTIONS

Table 8.14 ENG_FHMBPWR

MOLEX (10W) I/LOCK BOX PWR 1 PIN 1 PIN 2 PINS 3 TO 6 PIN 7 PINS 8 TO 10 24V GROUND PL31 PIN 6 BLACK SIGNAL MOLEX (8W) FHMB1 PL31 CHASSIS GND +24V PL31 PIN 1 PL31 PIN 2 BLACK WHITE/ORANGE SCREEN TWIST FHMB PL31 PIN 6 WIRE COLOUR COMMENTS

8.1.12 CAN3_ENG (9970-0147)

Table 8.15 CAN3_ENG
5 D TYPE PLG PIN 1 PIN2 SIGNAL CHASSIS GND CAN GND 15 D TYPE SKT PIN 1 PIN2 BLACK / RED BLACK / WHITE PIN 3 CAN +5V PIN 3 RED / BLACK WHITE / BLACK PIN 4 PIN 5 PIN 6 CAN CAN + RESET PIN 4 PIN 5 PIN 6 BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK (TWISTED PAIR WITH PIN 9) (TWISTED PAIR WITH PIN 7) (TWISTED PAIR WITH PIN 5) COLOUR COMENTS CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 7

RESET +

PIN 7

PIN 8

INDEX-

PIN 8

PIN 9

INDEX +

PIN 9

PIN 10

NO CONNECTION E_CLKE_CLK+

PIN 10

PIN 11 PIN 12

PIN 11 PIN 12

BLACK / BLUE BLUE / BLACK

(TWISTED PAIR WITH PIN 12)

Label FHM B 1 SK3 pin 1

Label PTM PANEL CAN B pin 1

900 mm

L UXEL P LATESETTER VOLUME 2 (8-11)

8.1.13 PUMP/PTM_PWR (9970-0150)

Label I/LOCK BOX PTM GREEN/YELLOW Label CHASSIS
130 mm

Label LIVE DIST BROWN BLUE Label NEUT DIST

30 mm

Label PANEL PTM

30 mm 220 mm 150 mm 1550 mm 300 mm

BROWN BLUE GREEN/YELLOW BROWN

100 mm

Label FUSE BROWN

220 mm

220 mm

BLUE
30 mm

80 mm

GREEN/YELLOW

BLUE Label REL 7 Label CHASSIS

Label I/LOCK BOX PTM

100 mm

GREEN/YELLOW

Label PUMP OUTLET

8.1.14 FEED_INT (9970-0152)

600 mm 250 mm Label: PTM NTERLOCK 400 mm Label: ENG PANEL ILOCK and Part number on Heatshrink Tie wraps Label INT SYSTEM

Table 8.16 FEED_INT

MOLEX 10W PIN 1 PIN 2 NO LOOP INTO I/ LOCKS NC LOOP FUSED S/W COMMON SIGNAL MOLEX 8W PIN 1 PIN 2 MOLEX 6W

PIN 3 PIN 4 PIN 5 PIN 6

PIN 3 PIN 4 PIN 5

NC LOOP FROM I/LOCK NC LOOP RETURN S/W FEEDBACK 1L6_F CONTACTOR F CONTACTOR R

PIN 6

PIN 7

PIN 7

PIN 8

PIN 8

PIN 9 PIN 10

PIN 3 PIN 4

VOLUME 2 (8-12) S YSTEM C ABLING DESCRIPTIONS

8.1.15 CAN5_INT (9970-0155)

Label FHMB3 SK3 pin 1 PLG 820 mm Label ENG PANEL CAN A

pin 1 SKT

Table 8.17 CAN5_INT

15 D TYPE PLG PIN 1 PIN2 SIGNAL CHASSIS GND CAN GND 15 D TYPE SKT PIN 1 PIN2 BLACK / RED BLACK / WHITE PIN 3 CAN +5V PIN 3 RED / BLACK WHITE / BLACK PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 CAN CAN + RESET RESET + INDEXINDEX + NO CONNECTION E_CLKE_CLK+ 0V CAN_SIG_RTN NO CONNECTION PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK (TWISTED PAIR WITH PIN 9) (TWISTED PAIR WITH PIN 7) (TWISTED PAIR WITH PIN 5) COLOUR COMMENTS CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 11 PIN 12 PIN 13 PIN 14 PIN 15

PIN 11 PIN 12 PIN 13 PIN 14 PIN 15

BLACK / BLUE BLUE / BLACK BLACK / BROWN BROWN / BLACK

(TWISTED PAIR WITH PIN 12)

(TWISTED PAIR WITH PIN 14)

8.1.16 PWR3_INT (99700156)

Label ENG PANEL PWR and Part number pin 1 120 mm 200 mm pin 1 Label FHMB3 PL31 pin 1 Approx 50 mm Cable tie 1700 mm Label FHMB2 PL31

Label REL 7 760 mm 25 m m Label REL 9

Table 8.18 PWR3_INT

ENG PANEL PWR SIGNAL FHMB2/FHMB3 WIRE COLOUR COMMENTS

L UXEL P LATESETTER VOLUME 2 (8-13)

Table 8.18 PWR3_INT (Continued)

PIN 1 CHASSIS GND FHMB 3 PL31 PIN 1 FHMB 2 PL31 PIN 1 PIN 2 +24V FHMB 2 PL31 PIN 2, REL 7 (FASTON) PIN 3 PIN 4 PIN 5 PIN 6 24V GROUND FHMB 2 PL31 PIN 6 REL 9 (FASTON) FHMB 3 PL31 PIN 6 BLACK +24V FHMB 3 PL31 PIN 2 WHITE/ORANGE WHITE/ORANGE TWIST WITH FHMB 2 PL31 PIN 6, TWIST WITH REL 9 TWIST WITH FHMB 3 PL31 PIN 6 BLACK SCREEN

PIN 7 PIN 8

24V GROUND

BLACK

8.1.17 CAN3_INT (9970-0157)

Label ENG Panel CAN B Cable 1 700 mm 550 mm 290 mm Cable 1 Label FHM B2 SK1

Cable 2 320 mm Tie wraps every 100mm Label FHM B3 SK1

220 mm

Label FHM B2 SK3 Cable 2

Table 8.19 CAN3_INT

15 D TYPE PLG PIN 1 PIN2 SIGNAL CHASSIS GND CAN GND 15 D TYPE PLG PIN 1 PIN2 BLACK / RED BLACK / WHITE PIN 3 CAN +5V PIN 3 RED / BLACK WHITE / BLACK PIN 4 PIN 5 PIN 6 CAN CAN + RESET PIN 4 PIN 5 PIN 6 BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK ( (TWISTED PAIR WITH PIN 9) (TWISTED PAIR WITH PIN 7) (TWISTED PAIR WITH PIN 5) COLOUR COMMENTS CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 7

RESET +

PIN 7

PIN 8

INDEX-

PIN 8

PIN 9

INDEX +

PIN 9

PIN 10

NO CONNECTION E_CLKE_CLK+ 0V CAN_SIG_RTN

PIN 10

PIN 11 PIN 12 PIN 13 PIN 14

PIN 11 PIN 12 PIN 13 PIN 14

BLACK / BLUE BLUE / BLACK BLACK / BROWN BROWN / BLACK

(TWISTED PAIR WITH PIN 12)

(TWISTED PAIR WITH PIN 14)

VOLUME 2 (8-14) S YSTEM C ABLING DESCRIPTIONS

Table 8.19 CAN3_INT (Continued)

PIN 15 NO CONNECTION PIN 15

8.1.18 ENG_M7 (9970-0159)

L a b e l F H M B 4 P L 3 0 p in 1 L a b e l P R O C M 7 P A N E L

9 5 0

m m

Table 8.20 ENG_M7

6 WAY JST PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 SIGNALS OUT A OUT C +24V +24V OUT B OUT D NOT USED NOT USED NOT USED NOT USED 10 WAY MOLEX PIN 2 TWIST PAIR WITH 6 WAY PIN 5 PIN 4 TWIST PAIR WITH 6 WAY PIN 6 PIN 3 TWIST PAIR WITH 6 WAY PIN 4 PIN 8 PIN 7 PIN 9 PIN 1 PIN 5 PIN 6 PIN 10

L UXEL P LATESETTER VOLUME 2 (8-15)

8.1.19 RIB/RIB2 (9970-0161)

View from non connection sides pin 1 CABLE 1 200 mm

Label FHMB 4 PL18" As close as possible to connector Label DIST BD PL5" As close as possible to connector

570 mm

350 mm

View from non connection sides pin 1

CABLE 2 190 mm

Label FHMB 4 PL19" As close as possible to connector Label 24V DIST PL11" As close as possible to connector

630 mm

pin 1 270 mm

8.1.20 BUFF_M7 (9970-0168)

Part number Label PANEL pin 1 100 mm Label M 7

Table 8.21 BUFF_M7

6 WAY JST PIN 6 SIGNALS OUT A 10 WAY MOLEX PIN 2 TWIST PAIR WITH 6 WAY PIN 2 PIN 4 TWIST PAIR WITH 6 WAY PIN 1 PIN 3 TWIST PAIR WITH 6 WAY PIN 3 PIN 8 PIN 7 PIN 9 PIN 1 PIN 5 PIN 6 PIN 10

PIN 5

OUT C

PIN 4

+24V

PIN 3 PIN 2 PIN 1

+24V OUT B OUT D NOT USED NOT USED NOT USED NOT USED

VOLUME 2 (8-16) S YSTEM C ABLING DESCRIPTIONS

8.1.21 INT_S62/S71 (9970-0177)

Label FHMB 2 PL9 Label S62

520 mm 30 mm

Label S71

Table 8.22 INT_S62/S71

AMP CT PIN 1 PIN 2 PIN 3 PIN 4 SIGNALS NOT USED X DIRECETION DOOR UP SUPPLY X DIRECETION DOOR UP GROUND X DIRECETION DOOR UP SIGNAL S62 PIN 1 S62 PIN 2 S62 PIN 3 TWISTED PAIR WITH S62 PIN 2 AMP EI

PIN 5 PIN 6 PIN 7 PIN 8

NOT USED X DIRECETION DOOR DOWN SUPPLY X DIRECETION DOOR DOWN GROUND X DIRECETION DOOR DOWN SIGNAL S71 PIN 1 S71 PIN 2 S71 PIN 3 TWISTED PAIR WITH S71 PIN 2

8.1.22 INT_S56/57/65 (9970-0178)

Label DIST PL6" Cable 1 Label DIST PL9" Label S56 30 mm 100 mm 960 mm Label S57 40 mm Label S65 - 1 Cable 2 Label FHMB 2 PL23" Label S65 - 4 390 mm Cable 2 Cable 1

Table 8.23 INT_S56/57/65

AMP CT PL 6 PIN 1 PL 6 PIN 2 PL 6 PIN 3 PL 6 PIN 4 PL 9 PIN 1 PL 9 PIN 2 PL 9 PIN 3 PL 9 PIN 4 PL 23 PIN 1 SIGNALS NOT USED RETARD UP SUPPLY RETARD UP GROUND RETARD UP SIGNAL NOT USED RETARD DOWN SUPPLY RETARD DOWN GROUND RETARD DOWN SIGNAL NOT USED S57 PIN 1 S57 PIN 2 S57 PIN 3 TWISTED PAIR WITH S57 PIN 2 S56 PIN 1 S56 PIN 2 S56 PIN 3 TWISTED PAIR WITH S56 PIN 2 AMP EI

L UXEL P LATESETTER VOLUME 2 (8-17)

Table 8.23 INT_S56/57/65 (Continued)

PL 23 PIN 2 PL 23 PIN 3 PL 23 PIN 4 NOT USED CASS AT NUDGER GND CASS AT NUDGER SIGNAL S65-1 FASTONTWISRED PAIR WITH OTHER FASTON S65-4 FASTON

8.1.23 ENG_S4 (9970-0183)

Label DIST O/P PL2 pin 1 730 mm pin 1 Label S4

Table 8.24 ENG_S4

AMP CT PIN 1 PIN 2 PIN 3 PIN 4 SIGNALS PLATE IN OUTPUT PUL_GND PLATE IN OUTPUT SUPPLY PLATE IN OUTPUT GROUND PLATE IN OUTPUT GND SIGNAL AMP CT S4 PIN 1 TWISTED PAIR WITH S4 PIN 2 S4 PIN 2 S4 PIN 3 TWISTED PAIR WITH S4 PIN 4 S4 PIN 4

8.1.24 INT_S49/S50 (9970-0186)

Label DIST PL8" 140 mm 880 mm 90 mm Label S49

120 mm Label 24V DIST PL7"

Label S50

Table 8.25 INT_S49/S50

AMP CT PL 8 PIN 1 PL 8 PIN 2 PL 8 PIN 3 PL 8 PIN 4 PL 7 PIN 1 PL 7 PIN 2 PL 7 PIN 3 PL 7 PIN 4 PLATE AT PRE DIVERTER PLATE AT PRE DIVERTER PLATE AT PRE DIVERTER SIGNALS RETARD MADE PUL_GND RETARD MADE SUPPLY RETARD MADE GROUND RETARD MADE SIGNAL AMP CT S49 PIN 1 TWISTED PAIR WITH S49 PIN 2 S49 PIN 2 S49 PIN 3 TWISTED PAIR WITH S49 PIN 4 S49 PIN 4 NO CONNECTION S50 BROWN WIRE S50 BLACK WIRE S50 BLUE WIRE

VOLUME 2 (8-18) S YSTEM C ABLING DESCRIPTIONS

8.1.25 ENG_S5 (9970-0187)

Label DIST O/P PL8

Label S5 730 mm

Table 8.26 ENG_S5

AMP CT PL8 PIN 1 SIGNALS PLATE LEFT OUTPUT PUL_GND PLATE LEFT OUTPUT SUPPLY PLATE LEFT OUTPUT GROUND PLATE LEFT OUTPUT SIGNAL AMP CT S5 PIN 1 WISTED PAIR WITH S5 PIN 2

PL8 PIN 2 PL8 PIN 3 PL8 PIN 4

S5 PIN 2 S5 PIN 3 TWISTED PAIR WITH S5 PIN 4 S5 PIN 4

8.1.26 INT_S52 (9970-0188)

Label DIST PL2 pin 1 1000 mm pin 1 Label S52

Table 8.27 INT_S52

AMP CT PIN 1 PIN 2 PIN 3 PIN 4 SIGNALS PARK POS PRE INPUT PUL_GND PARK POS PRE INPUT SUPPLY PARK POS PRE INPUT GROUND PARK POS PRE INPUT SIGNAL AMP CT S52 PIN 1 TWISTED PAIR WITH S52 PIN 2 S52 S52 S52 PIN 2 PIN 3 TWISTED PAIR WITH S52 PIN 4 PIN 4

8.1.27 ENG_S10/11 (9970-0190)

30 mm Label S10" 50 mm 230 mm Label DIST O/ Label S11" 50 mm 80 mm Label DIST O/ P PL12" P PL9" Label DIST O/ P PL6"

Table 8.28 ENG_S10/11

AMP CT PL6 PIN 1 PL6 PIN 2 PL6 PIN 3 PL6 PIN 4 SIGNALS NOT USED REG MOTOR OUT POS SUPPLY REG MOTOR OUT POS GROUND REG MOTOR OUT POS SIGNAL S10 PIN 1 S10 PIN 2 S10 PIN 3 TWISTED PAIR WITH S10 PIN 2 AMP EI

L UXEL P LATESETTER VOLUME 2 (8-19)

Table 8.28 ENG_S10/11 (Continued)

PL9 PIN 1 PL9 PIN 2 PL9 PIN 3 PL9 PIN 4 NOT USED REG MOTOR IN POS SUPPLY REG MOTOR IN POS GROUND REG MOTOR IN POS SIGNAL S11 PIN 1 S11 PIN 2 S11 PIN 3 TWISTED PAIR WITH S10 PIN 2

PL12 PIN 1 PL12 PIN 2 PL12 PIN 3 CAN ID GND LINK TO PL 12 PIN 3

8.1.28 ENG_S14/12/3 (9970-0194)

580 mm Approx 344 mm 800 mm 670 mm

Approx

344 mm

Label S13 Label S12

550 mm 310 mm 130 mm 100 mm 210 mm

This end piece has the pins fo Label Label DIST O/P PL7" 24V DIST PL2" Label DIST O/P PL11" DIST O/P PL10"

Label S14

Label S3
50 mm

This end piece has the pins for the links

Label PL11" Label SK11" 50 mm Label PL10" Label SK10"

Label

Cable free to move within the chain

28 mm radius

12 mm

Table 8.29 ENG_S14/12/3

AMP CT PL7 PIN 1 PL7 PIN 2 PL7 PIN 3 PL7 PIN 4 SIGNALS NOT USED CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL S14 S14 S14 2 S3 S3 S3 S3 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S14 PIN AMP EI

PL2 PIN 1 PL2 PIN 2 PL2 PIN 3 PL2 PIN 4 (DRAG CHAIN ASSY) PL10 PIN 1 PL10 PIN 2 (DRAG CHAIN ASSY)

DETECT LE PUNCH PUL GND DETECT LE PUNCH SUPPLY DETECT LE PUNCH GROUND DETECT LE PUNCH SIGNAL

PIN 1 PIN 2 PIN 3 PIN 4

TWISTED PAIR WITH S3 PIN 2

TWISTED PAIR WITH S3 PIN 4

CENTERING RH DETECT GROUND CENTERING RH DETECT SIGNAL

S12 S12

PIN1 PIN2

VOLUME 2 (8-20) S YSTEM C ABLING DESCRIPTIONS

Table 8.29 ENG_S14/12/3 (Continued)

PL11 PIN 1 PL11 PIN 2 DIST O/P PL11 PIN 1 DIST O/P PL11 PIN 2 DIST O/P PL11 PIN 3 DIST O/P PL11 PIN 4 DIST O/P PL10 PIN 1 DIST O/P PL10 PIN 2 DIST O/P PL10 PIN 3 DIST O/P PL10 PIN 4 CENTERING LH DETECT GROUND CENTERING LH DETECT SIGNAL NOT USED NOT USED CENTERING LH DETECT GROUND CENTERING LH DETECT SIGNAL NOT USED NOT USED CENTERING RH DETECT GROUND CENTERING RH DETECT SIGNAL SK10 SK10 PIN1 PIN2 SK11 SK11 PIN1 PIN2 S13 S13 PIN1 PIN2

8.1.29 ENG_S8/S9 (9970-0195)

Label INPUT DIST PL6" 60 mm

Label 850 mm

Label INPUT DIST PL9"

Label
Label INPUT DIST PL12" 80 mm

90 mm

Table 8.30 ENG_S8/S9

AMP CT (PL6) PIN 1 (PL6) PIN 2 (PL6) PIN 3 (PL6) PIN 4 SIGNALS NOT USED PUNCH MOTOR ON SUPPLY PUNCH MOTOR ON GROUND PUNCH MOTOR ON SIGNAL S8 PIN 1 S8 PIN 2 S8 PIN 3 TWISTED PAIR WITH S8 PIN 2 AMP EI

(PL9) PIN 1 (PL9) PIN 2 (PL9) PIN 3 (PL9) PIN 4

NOT USED PUNCH MOTOR OFF SUPPLY PUNCH MOTOR OFF GROUND PUNCH MOTOR OFF SIGNAL S9 PIN 1 S9 PIN 2 S9 PIN 3 TWISTED PAIR WITH S8 PIN 2

PL12 PIN 1 PL12 PIN 2 PL12 PIN 3 CAN ID GND LINK TO PL 12 PIN 3

L UXEL P LATESETTER VOLUME 2 (8-21)

8.1.30 INT_M22ASSY (9970-0198)

Label PUM P REL A Label PUM P REL B
30 mm 850 mm

Label 24V DIST PL8

190 mm 300 mm 80 mm 510 mm

Label B M24

Label FHM B 3 PL2 Label BM

30 mm 40 mm 170 mm 50 mm 20 mm 570 mm

Label BM 22
20 mm 30 mm 70 mm

Sleeve
530 mm

Label FHM B 3 PL1 Label FHM B3 PL22 Label FHM B3 PL20 L b l FHM B 3 PL10 Label B V20

Table 8.31 INT_M22ASSY

AMP 3 WAY PL15 PIN 1 PL15 PIN 3 PL15 PIN 2 SIGNALS NOT USED DC_MOT_A DC_MOT_B MOLEX BM24 BM24 BM24 PIN 1 PIN 3 PIN 2 RED TWISTED PAIR WITH BM24 PIN 3 BLACK (NOTE THIS MOTOR PIN OUT IS REVERSED) PL20 PIN 1 PL20 PIN 3 PL20 PIN 2 PL22 PIN 1 PL22 PIN 3 PL22 PIN 2 PL10 PIN 1 PL10 PIN 2 PL10 PIN 3 8 W MOLEX PL1 PIN 1 PL1 PIN 2 PL1 PIN 3 PL1 PIN 4 PL1 PIN 5 PL1 PIN 6 PL1 PIN 7 PL1 PIN 8 2 W MOLEX PL2 PIN 2 PL2 PIN 1 24 V GND NOT USED PL8 PIN 1 BLACK NOT USED NOT USED NOT USED NOT USED +24V SOL 1 +24V SOL 2 (BV24) (BV24) PUMP REL A PUMP REL B PL 8 PIN 2 PL 8 PIN 3 GREEN TWISTED PAIR WITH BV23 BLACK YELLOW TWISTED PAIR WITH BV8 PIN 3 BLACK NOT USED DC_MOT_A DC_MOT_B NOT USED DC_MOT_A DC_MOT_B NOT USED DC_MOT_A DC_MOT_B BM22 BM22 BM22 BM23 BM23 BM23 BV20 BV20 BV20 PIN 1 PIN 2 PIN 3 PIN 1 PIN 2 PIN 3 PIN 1 PIN 2 PIN 3 RED TWISTED PAIR WITH BV20 PIN 3 BLACK RED TWISTED PAIR WITH BM23 PIN 3 BLACK RED TWISTED PAIR WITH BM22 PIN 3 BLACK WIRE COLOUR

VOLUME 2 (8-22) S YSTEM C ABLING DESCRIPTIONS

8.1.31 INT_S55/59 (9970-0210)

Label 24V DIST PL12

350 mm

750 mm

Label 24V DIST PL9

Label S59 80 mm Label S55

Tie wraps Rubber Sleeve 100 mm

Label 24V DIST PL3

Table 8.32 INT_S55/59

AMP CT PL9 PIN 1 SIGNALS PLATE PAST DIVERTER PUL_GND PLATE PAST DIVERTER SUPPLY PLATE PAST DIVERTER GROUND PLATE PAST DIVERTER SIGNAL AMP CT S59 PIN 1 TWISTED PAIR WITH S59 PIN 2

PL9 PIN 2

S59 PIN 2

PL9 PIN 3

S59 PIN 3 TWISTED PAIR WITH S59 PIN 4

PL9 PIN 4

S59 PIN 4

AMP CT PL3 PIN 1 PL3 PIN 2 BROWN WIRE PL3 PIN 3 BLACK WIRE PL3 PIN 4 BLUE WIRE PL12 PIN 1 PL12 PIN 2 PL12 PIN 3 CAN ID GND LINK TO PL 12 PIN 3 NOT USED PAPER POST DIVERTER +24V PAPER POST DIVERTER SIGNAL PAPER POST DIVERTER GROUND S55

S55

S55

8.1.32 INT_S66/S53 (9970-0214)

Label 24V DIST PL6 100 mm 60 mm Label S66

910 mm 2 PIN Label DIST PL11 Label S53

Table 8.33 INT_S66/S53

AMP CT PL6 PIN 1 PL6 PIN 2 SIGNALS INTERLEAF NIP CLEAR PUL_GND INTERLEAF NIP CLEAR SUPPLY AMP CT S66 PIN 1 TWISTED PAIR WITH S66 PIN 2 S66 PIN 2

L UXEL P LATESETTER VOLUME 2 (8-23)

Table 8.33 INT_S66/S53

PL6 PIN 3 PL6 PIN 4 AMP CT PL11 PIN 1 PL11 PIN 2 PL11 PIN 3 PL11 PIN 4 NOT USED NUDGER DOWN LIMIT SUPPLY NUDGER DOWN LIMIT GROUND NUDGER DOWN LIMIT SIGNAL S53 PIN 1 S53 PIN 2 TWISTED PAIR WITH S53 PIN 1 INTERLEAF NIP CLEAR GROUND INTERLEAF NIP CLEAR SIGNAL S66 PIN 3 TWISTED PAIR WITH S66 PIN 4 S66 PIN 4 2 W MOLEX

8.1.33 INT_OUT (9970-0216)

95 mm 30 mm 40 mm 30 mm Cable ties every 100mm

Label FHMB2 PL14

Label FHMB2 PL24

Label FHMB2 PL26 Label ELV PANEL LOCK 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 40 mm Label ELV PAN Label FHMB2 PL8 Label FHMB2 PL10 Label FHMB2 PL15 Label FHMB2 PL16 50 mm

Table 8.34 INT_OUT

26 WAY PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 SIGNALS NOT USED SOL 0 SOL 1 SOL 2 SOL 3 BS74 BS75 NOT USED NOT USED NOT USED SOL 0 RTN SOL 1 RTN SOL 2 RTN SOL 3 RTN BS74 RTN BS75 RTN NOT USED NOT USED PL 1 PIN 4 PL 1 PIN 6 PL 1 PIN 8 PL 15 PIN 3 PL 24 PIN 4 PL 26 PIN 4 24 24 24 24 26 26 PL 1 PIN 3 PL 1 PIN 5 PL 1 PIN 7 PL 15 PIN 2 PL 24 PIN3 PL 26 PIN 3 24 24 24 24 26 26 TWIST PAIR 26W PIN 11 TWIST PAIR 26W PIN 12 TWIST PAIR 26W PIN 13 TWIST PAIR 26W PIN 14 TWIST PAIR 26W PIN 15 TWIST PAIR 26W PIN 16 AWG TWISTED PAIRS

VOLUME 2 (8-24) S YSTEM C ABLING DESCRIPTIONS

Table 8.34 INT_OUT (Continued)

PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 NOT USED NOT USED NOT USED BS73 BS73 RTN CONTACT_24VR TN NOT USED NOT USED PL 14 PIN 7 PL 14 PIN 8 6W MOLEX PIN 4 26 26 24 TWIST PAIR 26W PIN 23

PIN 25 PIN 26 14W MOLEX PIN 1 PIN 2 PIN 3 PIN 4

NOT USED LOCK BM28 CONTACT_24V PL 8 PIN 2 PL 16 PIN 3 6W MOLEX PIN 3 PL10 PIN 2 24 24 24 TWIST PAIR 14W PIN 9 TWIST PAIR 14W PIN 10

PIN 5

SUPPLY FOR BS78 NOT USED BS72 NOT USED LOCK RTN BM28 RTN NOT USED DOCK LIGHT RTN NOT USED BS72 RTN

24 OR 26

TWIST WITH 14W PIN 12

PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12

PL 14 PIN 3

26

TWIST PAIR 14W PIN 14

PL 8 PIN 3 PL 16 PIN 2

24 24

PL10 PIN 3

24 OR 26

PIN 13 PIN 14

PL 14 PIN 4

26

8.1.34 RIB7 (9970-0219)

View from non connection side Label FHMB POS2 PL18" Reverse side

580 mm

Label

ELV PANEL"

60 mm

Part number on reverse side

pin 1

st

Fold

nd

Fold

L UXEL P LATESETTER VOLUME 2 (8-25)

Table 8.35 RIB7

26 WAY PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 SIGNALS ANODE CATHODE GND SEN 8 GND SEN 9 +5V SEN 10 GND SEN 11 +5V PULSE SEN 8 PULSE SEN 9 PULSE SEN 10 PULSE SEN 11 5V SEN 16 GND SEN 0 5V SEN 1 GND SEN 2 5V SEN 3 BRD _ID0 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED 37 WAY PIN 1 PIN 20 PIN 2 PIN 21 PIN 3 PIN 22 PIN 4 PIN 23 PIN 5 PIN 24 PIN 6 PIN 25 PIN 7 PIN 26 PIN 8 PIN 27 PIN 9 PIN 28 PIN 10 PIN 29 PIN 11 PIN 30 PIN 12 PIN 31 PIN 13 PIN 32 PIN 14 PIN 33 PIN 15 PIN 34 PIN 16 PIN 35 PIN 17 PIN 36 PIN 18 PIN 37 PIN 19

VOLUME 2 (8-26) S YSTEM C ABLING DESCRIPTIONS

8.1.35 ENG_DIAGS (9970-0221)

Label SSB DIAGS pin 1 Label EXTPANEL DIAGS

pin 1

750mm

Table 8.36 ENG_DIAGS

9 D TYPE PLG PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 GROUND SIGNAL CHASSIS GND TX RX 9 D TYPE SKT PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 COMMENTS CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

8.1.36 ALERT (9970-0223)

Cable tie at break point Label EXT ALERT PANEL pin 1 270 mm 50 mm Label ALERT REL PIN 7 Label ALERT REL PIN 4

Table 8.37 ALERT

9 WAY D SKT PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 SIGNALS SPARE ALERT IN REL PIN 7 FASTON TWISTED PAIR WITH OTHER FASTON FASTON

ALERT OUT REL PIN 4 SPARE SPARE SPARE SPARE SPARE

L UXEL P LATESETTER VOLUME 2 (8-27)

8.1.37 INT_MAINS (9970-0226)

Label PTM PANEL 240 mm 80 mm 25 mm BLUE BROWN GN/YL Label ELV MAINS 900 mm BROWN Label PUMP REL 6 100 mm Label CHASSIS M5 GN/YL 55 mm Label PUMP REL 4 BLUE

Sleeve

8.1.38 RIB8 (9970-0229)

360 mm

120 mm

500 mm

140 mm Part number etc

Label ELV DIST PL5

Label PTM PANEL

View from non connection side

Table 8.38 RIB8

26 WAY PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 SIGNALS ANODE CATHODE GND SEN 8 GND SEN 9 +5V SEN 10 GND SEN 11 +5V PULSE SEN 8 PULSE SEN 9 PULSE SEN 10 PULSE SEN 11 5V SEN 16 GND SEN 0 26 WAY PIN 1 PIN 20 PIN 2 PIN 21 PIN 3 PIN 22 PIN 4 PIN 23 PIN 5 PIN 24 PIN 6 PIN 25 PIN 7 PIN 26 PIN 8 PIN 27 PIN 9 PIN 28 PIN 10

VOLUME 2 (8-28) S YSTEM C ABLING DESCRIPTIONS

Table 8.38 RIB8

PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 5V SEN 1 GND SEN 2 5V SEN 3 BRD _ID0 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED PIN 29 PIN 11 PIN 30 PIN 12 PIN 31 PIN 13 PIN 32 PIN 14 PIN 33 PIN 15 PIN 34 PIN 16 PIN 35 PIN 17 PIN 36 PIN 18 PIN 37 PIN 19

8.1.39 ELV_CTRL (9970-0230)

100 mm Label: INV AL0" Label: INV AL2" Label: INV BEHIND LID" 100 mm Label: INV L" Label: INV 6" Label: INV 4" Label: INV UPPER BLK" Label: ELEV BD PL1" 70 mm 1350 mm 100 mm 40 mm 80 mm 40 mm 100 mm Label: SIE 22NC" Tie wraps All 6mm tinned ends 50 mm 100 mm 100 mm Label: ELEV BD PL4" Label: INV LOWER BLK" All 80 mm Label: INV 3" Label: INV 2 Label: INV 1" Label: INV P24" Label: INV P24"

Label: SIE 21NC" Label: SIE A2-"

Label: INV CM2" Label: INV 12" Label: INV 11"

Table 8.39 ELV_CTRL

MOLEX PL4 PIN 1 PL4 PIN 2 PL4 PIN 3 PL4 PIN 4 PL4 PIN 5 PL4 PIN 6 PL4 PIN 7 PL4 PIN 8 SIGNAL P24V FWD NOT USED REV NOT USED FAST NOT USED RST 6MM TINNED RED LABEL: INV-6 6MM TINNED ORANGE LABEL: INV-3 6MM TINNED YELLOW LABEL: INV-2 ENDS 6MM TINNED 6MM TINNED COLOUR BLUE BROWN LABEL & COMMENTS LABEL: INV-P24 TWISTED WITH PIN 8 LABEL: INV-1 TWISTED WITH PIN 4

L UXEL P LATESETTER VOLUME 2 (8-29)

Table 8.39 ELV_CTRL (Continued)

PL4 PIN 9 PL4 PIN 10 PL4 PIN 11 PL4 PIN 12 PL1 PIN 1 PL1 PIN 2 PL1 PIN 3 PL1 PIN 4 LABEL INV-L LABEL INV AL2 LABEL INV AL0 NOT USED ALARM NOT USED OVERLOAD NOT USED BS73 BS73_RTN CONT_24V_R GND ALARM ALARM INPUT ALARM INPUT BLADE BLADE BLADE 6MM TINNED 6MM TINNED 6MM TINNED WHITE WHITE/ORANGE BLACK BLACK WHITE/BLUE BLUE LABEL: SIE-21NC TWISTED WITH PIN 3 LABEL: SIE-22NC LABEL: SIE-A2LABEL INV-CM2 LABEL INV-4 LABEL INV-P24 6MM TINNED BLACK LABEL: INV-11 6MM TINNED WHITE LABEL: INV-12 TWISTED WITH PIN 12

8.1.40 MAINS_ELV_IN (9970-0231)

0.25" FASTON Label CHASSIS PANEL" GREEN/YELLOW Label MAINS PTM Label 750 mm FILTER" 50 mm M5 100 mm 0.25" FASTON BROWN BLUE 0.25" FASTON Label FILTER" 0.25" FASTON Label GREEN/YELLOW 100 mm Label FRAME" M5

Label M5

PANEL"

GREEN/YELLOW 150 mm

Label M5

FRAME"

GREEN/YELLOW 450 mm

LID" M5

Label BROWN 0.25" FASTON 0.25" FASTON BLUE 40 mm Label FILTER" Label 35 mm 50 mm 40 mm

INV L1" M4 INSULATED FORK BROWN

55 mm

BLUE M4 INSULATED FORK INV N"

8.1.41 ELV_IN (9970-0236)

Label E LV C T RL SK 1 pin 1 Label PT M PA N EL

pin 1

500 mm

Table 8.40 ELV_IN

26 W PLG SIGNAL 26 W PLG COMMENTS

VOLUME 2 (8-30) S YSTEM C ABLING DESCRIPTIONS

Table 8.40 ELV_IN (Continued)

PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 NOT USED SOL 0 SOL 1 SOL 2 SOL 3 BS 74 BS 75 NOT USED NOT USED NOT USED SOL 0 RTN SOL 1 RTN SOL 2 RTN SOL 3 RTN BS74 RTN BS75 RTN NOT USED NOT USED NOT USED NOT USED NOT USED BS 73 BS73 RTN CONTACT 24 RTN NOT USED NOT USED PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16 PIN 17 PIN 18 PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24 PIN 25 PIN 26 (TWISTED PAIR WITH PIN 23) (TWISTED PAIR WITH PIN 11) (TWISTED PAIR WITH PIN 12) (TWISTED PAIR WITH PIN 13) (TWISTED PAIR WITH PIN 14) (TWISTED PAIR WITH PIN 15) (TWISTED PAIR WITH PIN 16)

8.1.42 ELV_LOCK (9970-0237)

Label PTM PANEL LOCK 750 mm 270 mm 50 mm Label TOP LIMIT 11 1250 mm 1600 mm Label ELV DIST PL4 Label ELV DIST PL3 80 mm 450 mm 700 mm 230 mm 60 mm Label DOCK LIGHT 70 mm 760 mm Label BS78 50 mm Label S70 70 mm Label BM28 Label S63

50 mm Labe

100 mm

Label LOCK

Table 8.41 ELV_LOCK

14 W MOLEX

L UXEL P LATESETTER VOLUME 2 (8-31)

Table 8.41 ELV_LOCK (Continued)

PIN 1 PIN 2 PIN 3 NOT USED LOCK DC_MOT_A 8W PIN 2 PIN 2 (BM28) 8W PIN 4 BS78 PIN 2 BLACK TWIST WITH PIN 9 RED TWIST PAIR WITH PIN 10 GREEN YELLOW

PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10

CONTACTOR_24V SUPPLY TO BS78 NOT USED BS72 NOT USED LOCK_RTN DC_MOT_B

8W PIN 3

RED TWIST WITH PIN 14

8W PIN 6 PIN 3 (BM28)

WHITE BLACK

PIN 11 PIN 12 PIN 13 PIN 14 M4 LABEL TOP LIMIT 11 BS78 PIN 3 BS77 PIN 3 AMP CT 4 WAY

NOT USED DOCK LIGHT RTN NOT USED BS72_RTN CONTACTOR_24V 8W PIN 7 8W PIN 8 ORANGE RED FASTON YELLOW

BS78 TO BS77 BS77 TO DOCK LIGHT

BS77 PIN 2 FASTON AMP EI 3 WAY

YELLOW YELLOW

PL4 PIN 1 PL4 PIN 2 PL4 PIN 3 PL4 PIN 4 PL3 PIN 1 PL3 PIN 2 PL3 PIN 3 PL3 PIN 4

NOT USED Z DIRECT DWN SUPP Z DIRECT DWN GND Z DIRECT DWN SIG NOT USED Z DIRECT UP SUPP Z DIRECT UP GND Z DIRECT UP SIG S63 S63 S63 PIN 1 PIN 2 PIN 3 TWIST PAIR WITH S63 PIN 2 S70 S70 S70 PIN 1 PIN 2 PIN 3 TWIS PAIR WITH S70 PIN 2

8.1.43 ELV_CON_24V (9970-0238)

Label: M4 red ring terminal 70 mm M4 red ring terminal Label: Bottom Tie wraps limit 12" 550 mm RED wire Label: SIE A1+" Place 80mm from this en Bottom limit 11" Part number here orange wire 1.65 m M4 ring

130 mm

VOLUME 2 (8-32) S YSTEM C ABLING DESCRIPTIONS

Table 8.42 ELV_CON_24V

WIRE NO. 1 END 1 M4 RED RING TERMINAL LABEL BOTTOM LIMIT 11 2 M4 RED RING TERMINAL LABEL BOTTOM LIMIT 12 SIGNAL ELEVATOR_ ENABLE_2 ELEVATOR_ ENABLE_3 END 2 M4 RED RING TERMINAL LABEL TOP LIMIT 12 INSULATED BLADE LABEL SIE A1+ RED WIRE COLOUR ORANGE

8.1.44 ENG_PROC (9970-0239)

Label: Bottom limit 11 Part number here orange wire M4 red ring terminal 70 mm M4 red ring terminal Tie wraps Label: Bottom limit 12 550 mm RED wire Label: SIE A1+ Place 80mm from this end 130 mm 1.65 m M4 red ring terminal

Table 8.43 ENG_PROC

9 D TYPE PLG PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 SIGNAL 1 SIGNAL 2 GROUND SIGNAL CHASSIS GND TX RX 9 D TYPE SKT PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 COMMENTS CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

8.1.45 MAINS_INT_PUMP (9970-0240)

Label PUMP RELAY REL 7" 40 mm BLUE M4 (x2) BROWN 650 mm 110 mm M5 Green / Yellow 30 mm 55 mm GREEN / YELLOW M4 Label CHASSIS" Label PUMP MOTOR" 0.25" Faston Label PUMP RELAY REL 9 Label CHASSIS" 30 mm Brown 50 mm Tie wraps 0.25" Faston x2 Brown 55 mm 50 mm Label C/BREAKER" 80 mm BLUE 0.25" Faston

L UXEL P LATESETTER VOLUME 2 (8-33)

8.1.46 MAINS_DIST (9970-0243)

FUSE HOLDER
20 mm 1 2 3 25 mm 260 mm

Label PSU 3 PIN BROWN BLUE BROWN BLUE

50 mm

4.8x0.5 FASTONS
70 mm

30 mm

Tie wrap at branch points and connector and every 100mm BROWN BLUE Label 3R 2T1 Label 3R 6T3

Label FILTER
430 mm 100 mm 30 mm

Part number here

100 mm

M5 Label CHASSIS GREEN/YELLOW GREEN/YELLOW

100 mm

M5

GREEN/YELLOW Label CHASSIS

Label CHASSIS M5

Label FILTER
100 mm

M4

8.1.47 INT_EMERG (9970-0246)

Label PANEL EMERG pin 1 310 mm 750 mm Label EMERG STOP SWITCH 50 mm Label EMERG STOP SWITCH MMI END 2300 mm 50 mm

Table 8.44 INT_EMERG

10W MOLEX PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 GND M4 EMERG STOP MMI END WHITE/ ORANGE +24V M4 EMERG STOP WHITE/ORANGE SIGNALS

PIN 6 M4 EMERG STOP LINK M4 EMERG STOP MMI END GREEN

VOLUME 2 (8-34) S YSTEM C ABLING DESCRIPTIONS

8.1.48 I/LOCK_DC (9970-0252)

100 mm 15 mm
70 mm 40 mm 30 mm

AES S14 AES A1+ AES S13 AES A240 mm 30 mm 70 mm

15 mm

5 mm
30 mm 70 mm 40 mm

AES 14

5 mm AES 13
110 mm

5 mm
30 mm 70 mm 40 mm

AES S21 AES 24 AES 23 AES S22 AES X1

30 mm 70 mm 40 mm

5 mm

10 mm
40 mm 40 mm

10 mm SIE A1+ SIE 21NC

40 mm 40 mm

SIE A2SIE 22NC SIE 6T3 SIE 4T2 SIE 2T1 F1A F2A F3A

40 mm

40 mm

20 mm

20 mm
40 mm 40 mm

SIE 5L3 SIE 3L2

20 mm 80 mm 10 mm 10 mm 10 mm 15 mm 50 mm 50 mm 50 mm

20 mm 80 mm 50 mm 50 mm 50 mm 10 mm 10 mm 10 mm 15 mm

SIE 1L1 F1B F2B F3B 50 mm 60 mm

50 mm 60 mm 40 mm 30 mm

40 mm

40 mm

40 mm 30 mm

100 mm

PWR IN

PWR 3

PWR 2

PWR 1
80mm

I/LOCKS

SHUTTER

AUX CONTACT MODUAL 51 NC 52 NC 25mm

Table 8.45 I/LOCK _DC

PIN SHUTTER PIN 1 SHUTTER PIN 2 SHUTTER PIN 3 SHUTTER PIN 4 SHUTTER PIN 5 SHUTTER PIN 6 NOT USED NOT USED AES 14 BLUE SIGNAL CHASSIS GND NOT USED AES 13 RED M5 COLOUR BLACK

L UXEL P LATESETTER VOLUME 2 (8-35)

Table 8.45 I/LOCK _DC

I/LOCK PIN 1 I/LOCK PIN 2 I/LOCK PIN 3 I/LOCK PIN 4 I/LOCK PIN 5 I/LOCK PIN 6 I/LOCK PIN 7 I/LOCK PIN 8 PWR1 PIN 1 PWR1 PIN 2 PWR1 PIN 3 PWR1 PIN 4 PWR1 PIN 5 PWR1 PIN 6 PWR1 PIN 7 PWR1 PIN 8 PWR1 PIN 9 PWR1 PIN 10 PWR2 PIN 1 PWR2 PIN 2 PWR2 PIN 3 PWR2 PIN 4 PWR2 PIN 5 PWR2 PIN 6 PWR2 PIN 7 PWR2 PIN 8 PWR2 PIN 9 PWR2 PIN 10 PWR3 PIN 1 PWR3 PIN 2 PWR3 PIN 3 PWR3 PIN 4 PWR3 PIN 5 PWR3 PIN 6 PWR3 PIN 7 PWR3 PIN 8 PWR3 PIN 9 PWR3 PIN 10 PWRIN PIN1 CHASSIS GND +24V +24V +36V +36V NOT USED 24V GND 24V GND 36V GND 36V GND CHASSIS GND +24V +24V +36V +36V NOT USED 24V GND 24V GND 36V GND 36V GND CHASSIS GND +24V +24V +36V +36V NOT USED 24V GND 24V GND 36V GND 36V GND CHASSIS GND PWR2 PIN 7 PWR2 PIN 8 PWR2 PIN 9 PWR2 PIN 10 M5 BLACK BLACK BLACK BLACK BLACK PWR1 PIN 7 PWR1 PIN 8 PWR1 PIN 9 PWR1 PIN 10 M5 PWR2 PIN 2 PWR2 PIN 3 PWR2 PIN 4 PWR2 PIN 5 BLACK BLACK BLACK BLACK BLACK WHITE / ORANGE WHITE / ORANGE WHITE / BROWN WHITE / BROWN PWRIN PIN 9 PWRIN PIN 8 PWRIN PIN 11 PWRIN PIN 11 M5 PWR1 PIN 2 PWR1 PIN 3 PWR1 PIN 4 PWR1 PIN 5 BLACK BLACK BLACK BLACK BLACK WHITE / ORANGE WHITE / ORANGE WHITE / BROWN WHITE / BROWN I_LOCK_STATE2 I_LOCK GROUND 51 NC F1A AES S22 SIE A1+ 52 NC F2A AES S14 SIE A2M5 SIE 2T1 SIE 2T1 SIE 4T2 SIE 4T2 BLACK YELLOW ORANGE VIOLET RED WHITE / GREEN WHITE / RED WHITE / BLUE BLACK WHITE / ORANGE WHITE / ORANGE WHITE / BROWN WHITE / BROWN

VOLUME 2 (8-36) S YSTEM C ABLING DESCRIPTIONS

Table 8.45 I/LOCK _DC

PWRIN PIN2 PWRIN PIN3 PWRIN PIN4 PWRIN PIN5 PWRIN PIN6 PWRIN PIN7 PWRIN PIN10 PWRIN PIN12 PWRIN PIN13 PWRIN PIN14 F3A SIE 22NC AES 23 AES S13 AES S21 AES 24 NOT USED SIE A2AES A2SIE 6T3 SIE 21NC AES X1 F3B F1B F2B SIE A1+ WHITE / BLUE ORANGE / BLACK ORANGE / RED RED / BLACK VIOLET / RED PINK GREY GREY / BLUE VIOLET +24V IN +24V IN +36V IN SIE 1L1 SIE 1L1 SIE 3L2 SIE 21NC AES A1+ SIE 5L3 WHITE / ORANGE WHITE / ORANGE WHITE / BROWN RED / BLACK RED / BLUE RED / BROWN

8.1.49 I/LOCK_EMERG (9970-0253)

Label 24V PSU (4 way) 40 mm 220 mm 30 mm Label EMERG (6 way) 100 mm M5 30 mm Label A1+ M4 Label A2Label CHASSIS

Tie wrap every 100mm

Table 8.46 I/LOCK_EMERG

6 WAY (EMERG) PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 24V GND 4W PIN 4 (24V PSU) BLACK CHASSIS 24V M5 M4 (A2-) BLACK WHITE/ORANGE

M4 (A1+)

24V

4W PIN 2 (24V PSU)

WHITE/ORANGE

L UXEL P LATESETTER VOLUME 2 (8-37)

8.1.50 INT_M20/M27 (9970-0255)

Label BM20 Label FHMB2 PL22 40 mm 680 mm 80 mm Label FHMB2 PL20 Label BM27 1150 mm Tie wraps every 100mm

30 mm

Table 8.47 INT_M20/M27

AMP 3 WAY PL22 PIN 1 PL22 PIN 3 PL22 PIN 2 SIGNALS RESERVED DC_MOT_A DC_MOT_B MOLEX BM20 BM20 BM20 PIN 1 PIN 3 PIN 2

NOTE THIS MOTOR PIN OUT IS REVERSED PL20 PIN 1 PL20 PIN 2 PL20 PIN 3 RESERVED DC_MOT_A DC_MOT_B BM27 BM27 BM27 PIN 1 PIN 2 PIN 3

8.1.51 INT_M25/M21 (9970-0256)

Label BM 25 Label FHM B3 PL16 220 mm 420 mm 300 mm Label FHM B3 PL29 50 mm Label BM 21 Tie wraps every 100mm

290 mm

Table 8.48 INT_M25/M21

JST 6 WAY PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 AMP CT (PL16) PIN 1 PIN 2 PIN 3 RESERVED DC_MOT_A DC_MOT_B SIGNALS OUT A OUT C +24 V +24 V OUT B OUT D JST 6 WAY + ADAPTER PIN 6 TWISTED PAIR WITH PIN JST 6WAY PIN 5 PIN 5 TWISTED PAIR WITH PIN JST 6WAY PIN 6 PIN 4 TWISTED PAIR WITH PIN JST 6WAY PIN 4 PIN 3 PIN 2 PIN 1 MOLEX (BM25) PIN 1 PIN 2 PIN 3

VOLUME 2 (8-38) S YSTEM C ABLING DESCRIPTIONS

8.1.52 ENG_M1 (9970-0281)

Label FHM B1 PL15 pin 1 300 mm Part number here Tie wrap at each end close to the connector Label M 1

Table 8.49 ENG_M1

AMP CT 3WAY PIN 1 PIN 3 PIN 2 SIGNALS RESERVED DC_MOT_A DC_MOT_B 3 WAY MOLEX MINIFIT PIN 1 PIN 2 PIN 3

8.1.53 ENG_M2 (9970-0282)

Label FHM B4 PL29 pin 1 300 mm Label M 2

1150 mm 25 mm sleeve at each end

Table 8.50 ENG_M2

JST 6 WAY PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 SIGNALS OUT A OUT C +24 V +24 V OUT B OUT D JST 6 WAY + ADAPTER PIN 6 TWISTED PAIR WITH PIN JST 6WAY PIN 5 PIN 5 TWISTED PAIR WITH PIN JST 6WAY PIN 6 PIN 4 TWISTED PAIR WITH PIN JST 6WAY PIN 4 PIN 3 PIN 2 PIN 1

8.1.54 ENG_M4 (9970-0283)

Label FHM B1 PL16 pin 1 1100 mm Part number here Tie wrap at each end close to the connector Label M 4

Table 8.51 ENG_M4

AMP CT 3WAY PIN 1 PIN 3 SIGNALS RESERVED DC_MOT_A 3 WAY MOLEX MINIFIT PIN 1 PIN 2 RED WIRE COLOUR

L UXEL P LATESETTER VOLUME 2 (8-39)

Table 8.51 ENG_M4

PIN 2 DC_MOT_B PIN 3 BLACK

8.1.55 INT_S45ASSY (9970-0284)

Label 24V DIST PL10"

Sleeve
Label DIST PL10" 100 mm 100 mm 170 mm

Label S47 Label S48 130 mm 70 mm

Label

24V DIST PL1"

60 mm 60 mm

670 mm

220 mm

Label S45 90 mm Label S46

Label

24V DIST PL4" 80 mm 290 mm

Label

DIST PL4"

Label S43

Label

DIST PL3"

90 mm

50 mm

Label S51

Table 8.52 INT_S45ASSY

AMP CT PL3 PIN 1 SIGNALS NUDGER DETECT PUL_GND AMP CT S48 PIN 1 TWISTED PAIR WITH S48 PIN 2 S48 PIN 2

PL3 PIN 2 PL3 PIN 3

NUDGER DETECT SUPPLY NUDGER DETECT GROUND

S48 PIN 3 TWISTED PAIR WITH S48 PIN 4 S48 PIN 4

PL3 PIN 4 PL4 PIN 1

NUDGER DETECT SIGNAL CASS EMPTY PUL_GND

S43 PIN 1 TWISTED PAIR WITH S43PIN 2 S43 PIN 2

PL4 PIN 2 PL4 PIN 3

CASS EMPTY SUPPLY CASS EMPTY GROUND

S43 PIN 3 TWISTED PAIR WITH S43 PIN 4 S43 PIN 4

PL4 PIN 4 PL10 PIN 1 PL10 PIN 2 PL10 PIN 3 PL10 PIN 4

CASS EMPTY SIGNAL NOT USED RETARD DOWN SUPPLY RETARD DOWN GROUND RETARD DOWN SIGNAL

S47 S47

PIN 1 PIN 2

S47 PIN 3 TWISTED PAIR WITH S47 PIN 2

24V PL4 PIN 1 24V PL4 PIN 2 24V PL4 PIN 3

NOT USED NUDGER DOWN LIMIT SUPPLY NUDGER DOWN LIMIT GROUND NUDGER DOWN LIMIT SIGNAL S45 S45 PIN 1 PIN 2

24V PL4 PIN 4

S45 PIN 3 TWISTED PAIR WITH S45 PIN 2

24V PL1 PIN 1 24V PL1 PIN 2 24V PL1 PIN 3 24V PL1 PIN 4

NOT USED NUDGER UP LIMIT SUPPLY NUDGER UP LIMIT GROUND NUDGER UP LIMIT SIGNAL S46 S46 PIN 1 PIN 2

S46 PIN 3 TWISTED PAIR WITH S46 PIN 2

24V PL10 PIN 1

NOT USED

VOLUME 2 (8-40) S YSTEM C ABLING DESCRIPTIONS

Table 8.52 INT_S45ASSY (Continued)

24V PL10 PIN 2 PAPER POST DIVERTER SUPPLY PAPER POST DIVERTER GROUND PAPER POST DIVERTER NAL SIGS51 BROWN WIRE

24V PL10 PIN 3

S51 BLACK WIRE

24V PL10 PIN 4

S51 BLUE WIRE

8.1.56 INT_S76 (9970-0285)

Label CASS ID PL1 Label S76

3450 mm

Table 8.53 INT_S76

CASS ID PL1 PIN 1 PIN 2 PIN 3 PIN 4 SIGNALS FRONT DOOR FRONT DOOR PUL_GND SUPPLY S76 PIN 1 TWIST PAIR WITH PIN 2 PIN 2 PIN 3 TWIST PAIR WITH PIN 4 PIN 4

FRONT DOOR GROUND FRONT DOOR SIGNAL

8.1.57 I/LOCK_PUMPCTRL (9970-0287)

Label PUMP CTRL 10 mm 210 mm Label REL A Fastons

100 mm Single tie wrap at each end

M5 Label CHASSIS

40 mm

Label REL B

Table 8.54 I/LOCK_PUMPCTRL

8 WAY MOLEX PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 REL B FASTON SIGNALS CHASSIS REL A M5 FASTON TWIST WITH PIN 4

L UXEL P LATESETTER VOLUME 2 (8-41)

8.1.58 BUFF_S19/20 (9970-0288)

Label Part No Label PANEL pin 1 150 mm 1150 mm Label S20 680 mm Label S19

Table 8.55 BUFF_S19/20

14W MOLEX PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 SIGNALS NOT USED BUFFER ENTRANCE PUL_GND BUFFER ENTRANCE GROUND BUFFER EXIT PUL_GND BUFFER EXIT GROUND NOT USED NOT USED NOT USED BUFFER ENTRANCE INPUT SUPPLY BUFFER ENTRANCE SIGNAL BUFFER EXIT INPUT SUPPLY BUFFER EXIT SIGNAL NOT USED NOT USED S19 PIN 2 S19 PIN 4 S20 PIN 2 S20 PIN 4 S19 PIN 1 TWISTED PAIR WITH S19 PIN 2 S19 PIN 3 TWISTED PAIR WITH S19 PIN 4 S20 PIN 1 TWISTED PAIR WITH S20 PIN 2 S20 PIN 3 TWISTED PAIR WITH S20 PIN 4 AMP CT

8.1.59 ENG_S19/20 (9970-0289)

Label Part No 50 mm Label PANEL pin 1 770 mm 50 mm Label DIST O/P PL3 Tie wraps Label DIST O/P PL4

Table 8.56 ENG_S19/20

14W MOLEX PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 SIGNALS NOT USED BUFFER ENTERANCE PUL_GND BUFFER ENTERENCE GROUND BUFFER EXIT PUL_GND BUFFER EXIT GROUND NOT USED PL4 PIN 1 TWISTED PAIR WITH PL4 PIN 2 PL4 PIN 3 TWISTED PAIR WITH PL4 PIN 4 PL3 PIN 1 TWISTED PAIR WITH PL3 PIN 2 PL3 PIN 3 TWISTED PAIR WITH PL3 PIN 4 AMP CT

VOLUME 2 (8-42) S YSTEM C ABLING DESCRIPTIONS

Table 8.56 ENG_S19/20 (Continued)

PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 NOT USED NOT USED BUFFER ENTERANCE INPUT SUPPLY BUFFER ENTERANCE SIGNAL BUFFER EXIT INPUT SUPPLY BUFFER EXIT SIGNAL NOT USED NOT USED PL4 PIN 2 PL4 PIN 4 PL3 PIN 2 PL3 PIN 4

8.1.60 ENG_S21 (9970-0291)

Label FHMB4 PL4 Label PHOTO DETECT

1350 mm

Table 8.57 ENG_S21

3 WAY AMP CT PIN 1 PIN 2 PIN 3 SIGNALS CATHODE ANODE NOT USED MOLEX 22-01-2045 PIN 2 (TWISTED WITH MOLEX PIN 1) PIN 1

8.1.61 ENG_S79 (9970-0292)

30 mm Label 24V DIST PL6 800 mm Label S79 -4 Label S79 -1

Table 8.58 ENG_S79

AMP CT PL 6 PIN 1 PL 6 PIN 2 PL 6 PIN 3 PL 6 PIN 4 SIGNALS NOT USED NOT USED CHAD TRAY HOME CHAD TRAY HOME RTN S79 -4 FASTON S79 -1 FASTON TWISRED PAIR WITH OTHER FASTON

L UXEL P LATESETTER VOLUME 2 (8-43)

8.1.62 MIX_FAN (9970-0295)

Cable ties every 700 mm 360 mm Label FHMB1 PL2

400 mm Label MIX FAN Part number at this end

Label FHMB1 PL23

Table 8.59 MIX_FAN

6W MOLEX PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 FAN GND FAN DETECT RTN PL2 PIN 2 PL23 PIN 4 FAN +24V FAN DETECT PL2 PIN 1 TWISTED PAIR WITH PL2 PIN 2 PL23 PIN 3 TWISTED PAIR WITH PL23 PIN 4 SIGNALS

8.1.63 MFAN (9970-0296)

30 mm Label MIX FAN 150 mm Label FAN + Label FAN -

Table 8.60 MFAN

6W MOLEX PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 FAN GND FAN DETECT RTN BLACK LABEL FANFAN +24V FAN DETECT RED YELLOW LABEL FAN+ TWIST WITH FANSIGNALS COLOUR

LINK TO 6W MOLEX PIN 6

8.1.64 BUFF_LOCK (9970-0298)

Part number Label PANEL Label I_LOCK

500 mm

Table 8.61 BUFF_LOCK

8WAY PIN 1 SIGNALS NOT USED 8 WAY PIN 1

VOLUME 2 (8-44) S YSTEM C ABLING DESCRIPTIONS

Table 8.61 BUFF_LOCK (Continued)

PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 N/O LOOP N/C LOOP S/W COMMON NOT USED N/O LOOP N/C LOOP S/W FEEDBACK PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8

8.1.65 PROC_COMMS (9970-0306)

Processor Ferrites Engine

4.5 metres

Table 8.62 PROC_COMMS

9W D TYPE STR SKT PIN 5 PIN 2 PIN 3 PIN 7 PIN 8 SIGNAL GND TX RX SIGNAL 1 SIGNAL 2 25W D TYPE STR PLUG PIN 7 PIN 3 PIN 2 PIN 4 PIN 5 (TP WITH 25WAY PIN 5) (TP WITH 25WAY PIN 2)

8.1.66 PSU_I/LOCK (9970-0310)

C a b le 1 15 m m L a b el PS U 3 PIN 6 m m T in n ed en d La b e l T A G 4 C a b le 2 M 5 L a b el FR A M E C a b le 3 La b e l + 2 4 V 100 m m 40 m m 6 m m T in n ed en d La b e l T A G 1

M 4 La b e l P SU

25 m m 30 m m

35 m m 1 0 m m T in n e d e n d L a b el + O U T 1 0 m m T in n e d e n d L a b el -O U T

Table 8.63 PSU_I/LOCK

CABLE 1 3 W PIN 1 3 W PIN 3 CABLE 3 4 W PIN 2 WH / OR +OUT BROWN BLUE TAG 1 TAG 4

L UXEL P LATESETTER VOLUME 2 (8-45)

Table 8.63 PSU_I/LOCK (Continued)

4 W PIN 4 BLACK -OUT

8.1.67 ELV_TLOCKSOL (9970-0379)

Label LOCK Part number here half way

20mm 100 mm

80 mm

10 mm 10 mm 5 mm

Table 8.64 ELV_TLOCKSOL

8 WAY MOLEX 8W PIN 2 SIGNAL NAME LABLE TINNED ENDS A1 WIRE COLOURS

LOCK

BLACK TWIST WITH 8 WAY PIN 6 GREEN

8W PIN 4

CONTACTOR_24V

21

8W PIN 3

BS72

11

RED TWIST WITH 8 WAY PIN 7

8W PIN 6

LOCK_RTN

A2

WHITE

8W PIN 7 8W PIN 8

BS72_RTN CONTACTOR_24V

12 22

ORANGE RED

8.1.68 ENG_BLOW (9970-0380)

Label DRUM VAC Place as near to the connector as possible

2.4m
340 mm 140 mm 30 mm 500 mm

50 mm

Label FHMB4 PL8 Place as near to the connector as possible Label FHMB4 PL10 Place as near to the connector as possible

Label DRUM BLOW Place as near to the connector as possible

Part number label

VOLUME 2 (8-46) S YSTEM C ABLING DESCRIPTIONS

Table 8.65 ENG_BLOW

PIN PL8 PIN 1 PL8 PIN 2 PL8 PIN 3 SIGNAL NOT USED SOL BV31 SOL BV31 RTN DRUM BLOW PIN 2 DRUM BLOW PIN 3 RED BLACK TWIST WITH PL8 PIN 3 PIN WIRE COMMENT

PL10 PIN 1 PL10 PIN 2 PL10 PIN 3

NOT USED SOL BV30 SOL BV30 RTN DRUM VAC DRUM VAC PIN 2 PIN 3 GREEN BLACK TWIST WITH PL10 PIN3

8.1.69 ENG_S3/S12 (9970-0406)

Cover this section with cable wrap 600 mm Approx 344 mm 790 mm 60mm Cover this section with cable wrap 625 mm Approx 344 mm

This end piece has the pins for the links Label S13

Label S12
155 mm 325 mm Chain must be able to bend in this direction. 540 mm Label Punch Frame Chain must be able to bend in this direction.

Label S14

Label S3

210 mm

100 mm

Label DIST O/P PL7 Label 24V DIST O/P PL2

40 mm

This end piece has the pins for the links

Part number here

Label PL11

Label DIST O/P PL11

60mm

Wire with cable wrap free to move within the chain

Label SK11 Label PL10

Label DIST O/P PL10

Label SK10

28 mm radius

30mm

Example

20mm

12 mm

Labels to be position as shown above from their connector

Use tie wraps every 100 mm where shown

8.1.70 ENG_S109/110 (9970-0390)

65 mm Label S110 720 mm Label FHMB4 PL9

Label S109

150 mm

Tie wraps every 100mm Label Part No etc Place 70mm from connector

Table 8.66 ENG_S109/110

SIGNALS PL9 PIN 1 NOT USED

L UXEL P LATESETTER VOLUME 2 (8-47)

Table 8.66 ENG_S109/110

PL9 PIN 2 PL9 PIN 3 PL9 PIN 4 PL9 PIN 5 PL9 PIN 6 PL9 PIN 7 PL9 PIN 8 SWING ROLLER IN DRUM SUPPLY SWING ROLLER IN DRUM GROUND SWING ROLLER IN DRUM SIGNAL NOT USED SWING ROLLER HOME SUPPLY SWING ROLLER HOME GROUND SWING ROLLER HOME SIGNAL S109 S109 S109 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S109 PIN 2 S110 S110 S110 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S110 PIN 2

8.1.71 ENG_S100/103 (9970-0392)

60 Label S100 Cable jacket only to cover this section with part no in centre 475 30 Label 24V DIST PL1

Label S103 60

position labels 25mm from connectors. 30 S100

Label 24V DIST PL4

Table 8.67 ENG_S100/103

AMP CT (24V DIST) PL4 PIN 1 PL4 PIN 2 PL4 PIN 3 PL4 PIN 4 PL1 PIN 1 PL1 PIN 2 PL1 PIN 3 PL1 PIN 4 SIGNALS AMP EI

NOT USED REG PIN MTR HOME SUPPLY REG PIN MTR HOME GROUND REG PIN MTR HOME SIGNAL NOT USED REG PIN MTR OUT SUPPLY REG PIN MTR OUT GROUND REG PIN MTR OUT SIGNAL S103 S103 S103 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S103 PIN 2 S100 S100 S100 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S100 PIN 2

VOLUME 2 (8-48) S YSTEM C ABLING DESCRIPTIONS

8.1.72 MAINS_PSU (9970-0420)

700 mm

Blue Brown Green/Yellow

35 mm

Label PSU

20mm

40 mm

Brown

50mm 100 mm

Blue Suppliers part number etc Label INLET Label CHASSIS

100 mm

Cable 1
150 mm M5 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)

8.1.73 PSU (9970-0421)

Label CHASSIS 120 mm 100 mm pin 1 Label PWR FILT PL4 40 mm Label SL2 +36V Label SL2 0V Label SL3 +5V (2 off) Label SL3 0V (2 off) 25 mm Label SL4 +24V (2 off) Label SL4 0V (2 off) 25 mm Label SL5 +24V (2 off) Label SL5 0V (2 off) 25 mm REFERENCE BREAKOUT POINT A 80 mm pin 1 Label PWR FILT PL5 Place labels close to the connector and then a cable tie to stop the wires straining the labels Label SL3

30 mm 70 mm

Label SL6 +15V(1) Label SL6 0V(1) Label SL6 +15V (2) Label SL6 0V(2)

50 mm 40 mm 40 mm

50 mm

L UXEL P LATESETTER VOLUME 2 (8-49)

Label next to connector, then a cable ties and then at 100mm spacing Label Part No Next to PL11 branch point Label EODD PL3 pin 1 300 mm 2 cable ties at 50/60 mm spacing along this 157mm section Label FAN1 70 mm 50 mm 80 mm 80 mm 50 mm

Label SSB PL17 100 mm 2 cable ties at 50mm spacing along this 150mm section

200 mm

TO REFERENCE POINT A Label next to connector, then a cable ties

170 mm

pin 1 Label LSB PL 11

pin 1 Label LSB PL13

80 mm

200 mm

pin 1 130 mm Label LSB PL 10

Table 8.68 PSU

FASTONS SIGNAL CONNECTORS WIRE COLOUR WHITE/ BROWN BLACK COMMENTS

M5 RING (SL2+36V)

+36V

PL4 PIN 10

TWIST WITH PL4 PIN4

M5 RING (SL2 0V) (REF 8) USE ABOVE M5

+36V_GND

PL4 PIN 4

36V TO CHASSIS GND LINK +5V +5V

M5 CHASSIS

BLACK

SL3 +5V USE ABOVE FASTON

PL5 PIN 3 PL13 PIN 3

RED RED

TWIST WITH PL5 PIN 1 TWIST WITH PL13 PIN 10 TWIST WITH PL13 PIN 11 TWIST WITH PL13 PIN 12

SL3 +5V

+5V

PL13 PIN 4

RED

USE ABOVE FASTON

+5V

PL13 PIN 5

RED

PL13 PIN 5 PL13 PIN 6 SL3 PIN1

LINK 5V LINK 5V +5V SENSE

PL13 PIN 6 PL3 PIN 6 PL13 PIN 2

RED RED RED/WHITE TWIST WITH PL3 PIN 2 TWIST WITH PL13 PIN 9

SL3 0V USE ABOVE FASTON USE ABOVE FASTON SL3 0V (REF 7) PL13 PIN 12 PL13 PIN 13 PL13 PIN 14 SL3 PIN2

+5V_GND +5V_GND +5V_GND +5V_GND LINK 0V LINK 0V LINK 0V 0V SENSE

PL 5 PIN 1 PL13 PIN 10 PL13 PIN 11 PL13 PIN 12 PL13 PIN 13 PL13 PIN 14 PL3 PIN 2 PL13 PIN 9

BLACK BLACK BLACK BLACK BLACK BLACK BLACK WHITE/ BLACK

VOLUME 2 (8-50) S YSTEM C ABLING DESCRIPTIONS

Table 8.68 PSU

SL4 +24V +24V PL4 PIN 1 WHITE/ ORANGE WHITE/ ORANGE WHITE/ ORANGE BLACK BLACK BLACK WHITE/ ORANGE WHITE/ ORANGE WHITE/ ORANGE TWIST WITH PL4 PIN 3 TWIST WITH PL4 PIN 5

USE ABOVE FASTON

+24V

PL4 PIN 6

TWIST WITH PL4 PIN 9

SL4 +24V

+24V

PL3 PIN 7

TWIST WITH PL3 PIN 3

SL4 0V (REF 6) USE ABOVE FASTON SL4 0V (REF 5) SL5 +24V

+24V_GND +24V_GND +24V_GND +24V

PL4 PIN 5 PL4 PIN 9 PL3 PIN 3 PL4 PIN 2

PL4 PIN 2

+24V

PL4 PIN 7

TWIST WITH PL4 PIN 8

PL4 PIN 7

+24V

F1 PIN 2

TWIST WITH F1 PIN 3

8.1.74 DISK DATA (9970-0423)

120 mm 680 mm

Label TERM

Label DISK Part Number etc (in centre) 85mm

Equates to pin 1

View from pin side

Label LSB2 SK11

8.1.75 MAINS_DIST (9970-0424)

20 mm BROWN BLUE Label FILTER BROWN 50 mm 20 mm BLUE 100 mm 100 mm Part number here (Cable 1) 100 mm 100 mm 30 mm 1 2 3 25 mm 260 mm 4.8x0.5 FASTONS 70 mm Tie wrap at branch points and connector and every 100mm 100 mm BROWN Label CB IN_L next to faston 430 mm BLUE Label CB IN_N next to faston FUSE HOLDER

Label PSU 3 PIN

M5

20 mm Label CHASSIS GREEN/YELLOW GREEN/YELLOW Label CHASSIS next to ring M5 50 mm 100 mm M4 Part number here (Cable 2)

Label CHASSIS 20 mm M5

GREEN/YELLOW

Label FILTER next to fork

L UXEL P LATESETTER VOLUME 2 (8-51)

8.1.76 CAN1 (9970-0425)

Label LSB CAN SOMB Part number Label VBOMB SK2

pin 1

20 mm 100 mm 1800 mm

20 mm

pin 1

Table 8.69 CAN1

15 D TYPE PLG PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 SIGNAL CHASSIS GND CAN GND CAN +5V CAN CAN + RESET RESET + INDEX15 D TYPE PLG PIN 1 PIN2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 BLACK / RED RED / BLACK BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK BLACK / WHITE BLACK / BLUE BLUE / BLACK BLACK / BROWN BROWN / BLACK (TWISTED PAIR WITH PIN 14) (TWISTED PAIR WITH PIN 15) (TWISTED PAIR WITH PIN 12) (TWISTED PAIR WITH PIN 9) (TWISTED PAIR WITH PIN 7) (TWISTED PAIR WITH PIN 5) COLOUR COMENTS CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 9

INDEX +

PIN 9

PIN 10 PIN 11 PIN 12 PIN 13 PIN 14

SPARE E_CLKE_CLK+ 0V CAN_SIG_RT N SPARE

PIN 10 PIN 11 PIN 12 PIN 13 PIN 14

PIN 15

PIN 15

WHITE / BLACK

8.1.77 VBOMB_PWR (9970-0427)

Label RFI BOX SOMB PWR pin 1 Part Number Label VBOMB PL 11 pin 1

20 mm 100 mm 2500 mm

20 mm

VOLUME 2 (8-52) S YSTEM C ABLING DESCRIPTIONS

8.1.78 24V_ENG (9970-0428)

14 W Recepticle) Label I/LOCK BOX PWR IN Label RFI BOX FHMB PWR 250 mm 300 mm 100 mm Part Number here 100 mm 120 mm (14 Way Plug) Label INT-SYSTEM Label RFI BOX I/LOCK (26 Way) 50 mm (8 Way)

Table 8.70 24V_ENG

PIN SIGNAL COLOUR

8 W PIN 1 8 W PIN 2 8 W PIN 3 8 W PIN 4 8 W PIN 5 8 W PIN 6 8 W PIN 7 8 W PIN 8 26 W PIN1 26 W PIN2 26 W PIN3 26 W PIN4 26 W PIN5 26 W PIN6 26 W PIN7 26 W PIN8 26 W PIN9

NOT USED +24V 24V GND +36V NOT USED +24V 24V GND 36V GND NOT USED NOT USED NOT USED 24V ILOCK NOT USED NOT USED NOT USED +24GND NOT USED 14 W (RECEPTACLE) PIN 13 BLACK 14 W (RECEPTACLE) PIN 6 ORANGE 14 W (RECEPTACLE) PIN 3 14 W (RECEPTACLE) PIN 9 14 W (RECEPTACLE) PIN 11 WH/OR BLACK BLACK 14 W (RECEPTACLE) PIN 2 14 W (RECEPTACLE) PIN 8 14 W (RECEPTACLE) PIN 4 WH/OR BLACK WH/BN

8.1.79 EDGE_LASER (9970-0434)

Table 8.71 EDGE_LASER
JST PHR-3 EDGE BD PL3 SIGNALS JST PHR-2 LASER COLOUR

PIN 1 PIN 2 PIN 3

NOT CONNECTED LASER POWER GROUND PIN 1 PIN 2 RED GREEN

L UXEL P LATESETTER VOLUME 2 (8-53)

8.1.80 VBOMB_SENSORS (99700435)

L a be l A P H O M E L a b el V B O M B P L 1 3 200mm 560m m 200m m 300 mm 200mm P a r t N o et c 600mm 500 mm Label N D H O M E L a b e l F O C U S L IM IT

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

Table 8.72 VBOMB_SENSORS

MOLEX 24W VBOMB PL13 SIGNALS

PIN 1 PIN 2 PIN 3

+5V 0V SPARE AMP 3W SENS LPD

PIN 4 PIN 5 PIN 6

+5V 0V SENS LPD

PIN 1 PIN 2 PIN 3

AMP 3W HOME ND

PIN 7 PIN 8 PIN 9

+5V 0V ND HOME

PIN 1 PIN 2 PIN 3

PIN 10 PIN 11 PIN 12

+5V 0V SPARE
AMP 3W HOME AP

PIN 13

+5V

PIN 1

VOLUME 2 (8-54) S YSTEM C ABLING DESCRIPTIONS

Table 8.72 VBOMB_SENSORS

PIN 14 PIN 15 0V AP HOME PIN 2 PIN 3
AMP 3W FOCUS OPR

PIN 16 PIN 17 PIN 18

+5V 0V FOCUS OPR

PIN 1 PIN 2 PIN 3

AMP 3W FOCUS LIMIT

PIN 19 PIN 20 PIN 21 PIN 22 PIN 23 PIN 24

+5V 0V FOCUS LIMIT NC NC NC

PIN 1 PIN 2 PIN 3

8.1.81 VBOMB_LPD (9970-0436)

Label LPD
100mm Part no etc

100 mm pin 1

pin 1
25mm

Label VBOMB PL3

1000 mm Max deviation is 45 degrees from the horizontal

Table 8.73 VBOMB_LPD

JST PHDR-10VS VBOMB PL3 SIGNALS JST PHDR-10VS LPD

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10

0V POWERDET 0V +15V 0V -15V NOT USED NOT USED NOT USED NOT USED

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10

L UXEL P LATESETTER VOLUME 2 (8-55)

8.1.82 VBOMB_LPDM (9970-0437)

Lab el LP D M O T O R P L1 5 p in 1
25 m m 100 mm P a rt N o e tc

Lab el LP D M O T p in 1

25 m m

2450

mm

Table 8.74 VBOMB_LPDM

JST HRP-06 LPD MOTOR PL15 SIGNALS DF11-6DS-2C LPD MOT

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

LPD MOTOR PHASE ORANGE LPD MOTOR PHASE RED +24V +24V LPD MOTOR PHASE BLUE LPD MOTOR PHASE YELLOW

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

8.1.83 VBOMB_APM (9970-0438)

L a b e l A P E R T U R E M O T O R PL16 p in 1
25m m 25m m P a rt N o e tc

Lab el A P M O T p in 1

100

mm

1570 mm

Table 8.75 VBOMB_APM

JST HRP-6 APERTURE MOTOR PL16 SIGNALS DF11-6DS-2C AP MOT

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

AP MOTOR PHASE ORANGE AP MOTOR PHASE RED +24V +24V AP MOTOR PHASE BLUE AP MOTOR PHASE YELLOW

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

VOLUME 2 (8-56) S YSTEM C ABLING DESCRIPTIONS

8.1.84 VBOMB_NDM (9970-0439)

L a b e l N D M O T O R P L 1 4 p in 1
25 mm P art N o etc

Lab el N D M O T p in 1

100

mm 780 mm

25m m

Table 8.76 VBOMB_NDM

JST HRP-06 MOTOR PL14 ND SIGNALS DF11-6DS-2C ND MOT

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

ND MOTOR PHASE ORANGE ND MOTOR PHASE RED +24V +24V ND MOTOR PHASE BLUE ND MOTOR PHASE YELLOW

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

8.1.85 VBOMB_FOCM (9970-0440)

L a b e l F O C U S M O T O R P L 1 7 p in 1
25 mm P art N o etc

Lab el FO C M O T p in 1

100

mm 1550 m m

25m m

Table 8.77 VBOMB_FOCM

JST HRP-06 FOCUS MOTOR PL17 SIGNALS DF11-6DS-2C FOC MOT

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

FOCUS MOTOR PHASE ORANGE FOCUS MOTOR PHASE RED +24V +24V FOCUS MOTOR PHASE BLUE FOCUS MOTOR PHASE YELLOW

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

L UXEL P LATESETTER VOLUME 2 (8-57)

8.1.86 PSU_CTRL (9970-0442)

P art n um b er
200 m m p in 1
F e r r it e

50 m m 450 m m

L a b e l K E Y N /O L a b e l K E Y N /O

P IN 3 P IN 4

p in 1
10 m m

150m m

L a b e l I/L C O N T A C T O R

900 m m L ab el L S B P S U C T R L 300 m m

p in 1

L a b e l I/ L O C K S H U T T E R

Table 8.78 PSU_CTRL

LSB PSU CTRL SIGNAL ILOCK_SHUTTER COLOUR COMENTS

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5

NOT USED NOT USED I_LOCK NOT USED GROUND

I/L CONTACTOR PIN 1

PIN 3

BLACK

TP WITH PIN 6

BLACK

TP WITH PIN 10

2 WAY MOLEX PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 NOT USED NOT USED NOT USED NOT USED I_LOCK_STATE2_IN
I/L CONTACTOR PIN2

WHITE

2 WAY MOLEX PIN 11 PIN 12 PIN 13 NOT USED INT_SUPPLY INT_STAT_KEYSWITC H NOT USED GND M4 FORK (KEY N/O PIN 4) BLACK PIN 6 M4 FORK (KEY N/O PIN 3) YELLOW BLUE TP WITH PIN 15

PIN 14 PIN 15

8.1.87 VBOMB_POD (9970-0443)

Label VBOMB PL5
75 mm

Pinout designation
Keep sleeving back by 75 mm

2 4 6

1 3 5 7 9 11 13

Label POD
Part No etc

pin 1
25 mm 100 mm 1170 mm 25 mm

pin 1

8 10 12 14

VOLUME 2 (8-58) S YSTEM C ABLING DESCRIPTIONS

Table 8.79 VBOMB_POD

JST PHDR-14VS VBOMB PL5 SIGNALS JST PHDR-14VS POD

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14

0V POWER PDX1Y1 0V PDX2Y1 0V PDX2Y2 0V PDX1Y2 0V +15V 0V POWER -15V 0V POWER NOT USED

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14

8.1.88 I/LOCK_MAIN (9970-0444)

60 mm 45 mm BLUE BROWN Label C/B OUT 0.25 FASTONS Cable 2 150 mm SOLDERED TAILS Label NEUTRAL FEED Label LIVE FEED Position labels at this end of the wires 55 mm 40 mm Label REL 4 Label REL 6 BLUE BROWN 0.25 FASTONS Cable 3 150 mm SOLDERED TAILS Label NEUTRAL Label LIVE BLUE BROWN BLUE BROWN

Label LID 140 mm M5 RINGS GREEN/YELLOW Cable 4

Label BOX M5 RINGS

L UXEL P LATESETTER VOLUME 2 (8-59)

8.1.89 ENG_S6/S15 (9970-0445)

Label FHMB4 PL12 (20mm from connector) 50 mm Label FHMB4 PL7
(20mm from connector)

Part number etc

(40mm from cable tie)

Cable tie

80 mm

Label S15
(20mm from connector)

Label S6 1040 mm 600 mm

(20mm from connector)

Table 8.80 ENG_S6/S15

AMP CT SIGNALS AMP EI

PL 7 PIN 1 PL 7 PIN 2 PL 7 PIN 3 PL 7 PIN 4 PL 12 PIN 1 PL 12 PIN 2 PL 12 PIN 3 PL 12 PIN 4

NOT USED PUSH BAR HOME SUPPLY PUSH BAR HOME GROUND PUSH BAR HOME SIGNAL NOT USED PUSH BAR FWD LIMIT SUPPLY PUSH BAR FWD LIMIT GROUND PUSH BAR FWD LIMIT SIGNAL S15 S15 S15 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S15 PIN S6 S6 S6 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S6 PIN 2

8.1.90 ENG_BLOW (9970-0446)

Label BV30 Label FHMB4 PL10
230mm 2650mm (sleeved) 50 mm 770mm 70mm

20mm

100mm

60mm

Label BV31 Sol Label BV40 Label BV31 Part number label Label FHMB1 PL10

Table 8.81 ENG_BLOW

AMP CT FHMB4 PL10 SIGNAL NAME MOLEX MINIFIT JR BV30 COMMENT

PIN 1 PIN 2

NOT USED MAIN VAC MANIFOLD BV30 PIN2 TWIST WITH BV30 PIN 3

VOLUME 2 (8-60) S YSTEM C ABLING DESCRIPTIONS

Table 8.81 ENG_BLOW

PIN 3 MAIN VAC MANIFOLD RTN BV30 PIN 3

FHMB1 PL10

BV40

PIN 1 PIN 2 PIN 3 MOLEX MINIFIT JR

BV31 SOL

NOT USED LEADING EDGE LEADING EDGE RTN BV40 PIN 2 BV40 PIN 3 TWIST WITH BV40 PIN 3

BV31

BV31 PIN 1 PIN 1 PIN 2 DRUM BLOW DRUM BLOW RTN BV31 PIN 2 BV31 PIN 3 TWIST WITH BV31 PIN2

8.1.91 I/LOCK_DC (9970-0447)

RELEASE COIL 1 40 mm 15 mm 210 mm RELEASE COIL 2 40 mm 5 mm 30 mm 70 mm 40 mm 5 mm 30 mm 70 mm 40 mm 10 mm AES S22 AES X1 40 mm 10 mm 40 mm Label 24V PSU 20 mm 40 mm 40 mm SIE 21NC SIE 5L3 SIE 3L2 80 mm SIE 1L1 30 mm 10 mm 10 mm 10 mm 15 mm 60 mm 40 mm 40 mm 30 mm 100 mm 30 mm 90 mm 30 mm 52NC 51NC 40 mm 50 mm F1B 50 mm F2B 50 mm F3B 50 mm 60 mm 60 mm 40 mm 40 mm F3A 50 mm F2A F1A SIE 2T1 SIE 22NC SIE 6T3 SIE 4T2 40 mm 40 mm 20 mm 40 mm SIE A1+ SIE A240 mm 40 mm AES 24 AES 23 30 mm 70 mm 5 mm AES S21 AES 14 AES S13 AES A240 mm 5 mm AES 13 110 mm 70 mm 30 mm AES S14 AES A1+ 30 mm 70 mm 15 mm 100 mm

20 mm

20 mm

80 mm 50 mm 50 mm 50 mm
10 mm 10 mm 10 mm 15 mm

EMERG

PWR IN

PWR 3

PWR 2

PWR 1

I/LOCKS

SHUTTER

L UXEL P LATESETTER VOLUME 2 (8-61)

Table 8.82 I/LOCK_DC

SIGNAL GUAGE COLOUR

SHUTTER PIN 1 (1) SHUTTER PIN 2 (1) SHUTTER PIN 3 (1) SHUTTER PIN 4 (1) SHUTTER PIN 5 (1) SHUTTER PIN 6 (1) I/LOCK PIN 1 (1) I/LOCK PIN 2 (1) I/LOCK PIN 3 (1) I/LOCK PIN 4 (1) I/LOCK PIN 5 (1) I/LOCK PIN 6 (1) I/LOCK PIN 7 (1) I/LOCK PIN 8 (2) I/LOCK PIN 8 (2) PWR1 PIN 1 PWR1 PIN 2 PWR1 PIN 3 PWR1 PIN 4 PWR1 PIN 5 PWR1 PIN 6 PWR1 PIN 7 PWR1 PIN 8 PWR1 PIN 9 (2) (2) (2) (1) (2) (2) (2) (2)

CHASSIS GND NOT USED

M5

(1)

18

BLACK

AES 13 (1) NOT USED NOT USED AES 14 (1) SW_FEEDBACK_1 51NC F1A (1) (1)

24

RED

24 18 24 24 24 24 24 24 24 24 (1) (2) (2) (2) (2) 18 18 18 18 18

BLUE BLACK YELLOW ORANGE VIOLET YELLOW WHITE / GREEN WHITE / RED WHITE / BLUE ORANGE / BLACK BLACK WHITE / ORANGE WHITE / ORANGE WHITE / BROWN WHITE / BROWN

AES S22 (1) SIE A1+ (2) SW_FEEDBACK_2 52NC F2A (1) (1)

AES S14 (1) ENG_24V_GND ENG_24V_GND CHASSIS GND +24V_ILOCKED +24V_ILOCKED +36V_ILOCKED +36V_ILOCKED NOT USED 24V GND 24V GND 36V GND 36V GND CHASSIS GND +24V_ILOCKED +24V_ILOCKED +36V_ILOCKED +36V_ILOCKED NOT USED PWRIN PIN 13 (2) PWRIN PIN 8 (2) SIE A2(2)

AES A2- (1) M5 SIE 2T1 SIE 2T1 SIE 4T2 SIE 4T2

18 18 18 18 18 18 18 18 18

BLACK BLACK BLACK BLACK BLACK WHITE / ORANGE WHITE / ORANGE WHITE / BROWN WHITE / BROWN

PWRIN PIN 11 (2) PWRIN PIN 11 (2) M5 (1) PWR1 PIN 2 (2) PWR1 PIN 3 (2) PWR1 PIN 4 (2) PWR1 PIN 5 (2)

PWR1 PIN 10 (2) PWR2 PIN 1 PWR2 PIN 2 PWR2 PIN 3 PWR2 PIN 4 PWR2 PIN 5 PWR2 PIN 6 PWR2 PIN 7 PWR2 PIN 8 PWR2 PIN 9 (2) (2) (2) (1) (2) (2) (2) (2)

24V GND 24V GND 36V GND 36V GND CHASSIS GND +24V_ILOCKED +24V_ILOCKED

PWR1 PIN 7 (2) PWR1 PIN 8 (2) PWR1 PIN 9 (2) PWR1 PIN 10 (2) M5 (1) PWR2 PIN 2 (2) PWR2 PIN 3 (2)

18 18 18 18 18 18 18

BLACK BLACK BLACK BLACK BLACK WHITE / ORANGE WHITE / ORANGE

PWR2 PIN 10 (2) PWR3 PIN 1 PWR3 PIN 2 PWR3 PIN 3 (1) (1) (2)

VOLUME 2 (8-62) S YSTEM C ABLING DESCRIPTIONS

Table 8.82 I/LOCK_DC

PWR3 PIN 4 PWR3 PIN 5 PWR3 PIN 6 PWR3 PIN 7 PWR3 PIN 8 PWR3 PIN 9 (1) (1) (1) (1) (1) +36V_ILOCKED +36V_ILOCKED NOT USED 24V GND 24V GND 36V GND 36V GND CHASSIS GND +24V IN +24V IN +36V IN NOT USED (1) (1) +24V_ILOCKED EODD_LASER_IL 24V GND NOT USED 24V GND EODD_LASER_ILR ENG_24V ENG_24V PWRIN PIN9 (2) SIE 6T3 (1) SIE 21NC (2) AES A1+ (1) 18 24 24 24 24 24 24 24 24 24 24 24 24 BLACK ORANGE / RED RED / BLACK RED / BLACK VIOLET / RED PINK GREY GREY / BLUE VIOLET RED / BLACK WHITE / BLUE BLACK WHITE/ORANGE PWR3 PIN 3 (2) SIE 5L3 (1) PWRIN PIN 9 (2) PWR2 PIN 7 (2) PWR2 PIN 8 (2) PWR2 PIN 9 (2) PWR2 PIN 10 (2) M5 (1) SIE 1L1 (2) SIE 1L1 (2) SIE 3L2 (1) 18 18 18 18 18 18 18 18 24 18 24 18 BLACK BLACK BLACK BLACK BLACK WHITE / ORANGE WHITE / ORANGE WHITE / BROWN RED / BLACK WHITE / ORANGE RED / BROWN BLACK PWR2 PIN 4 (2) PWR2 PIN 5 (2) 18 18 WHITE / BROWN WHITE / BROWN

PWR3 PIN 10 (1) PWRIN PIN1 (1) PWRIN PIN2 (1) PWRIN PIN3 (1) PWRIN PIN4 (1) PWRIN PIN5 PWRIN PIN6 PWRIN PIN7

PWRIN PIN 8 (2) PWRIN PIN10 PWRIN PIN13 (2) PWRIN PIN14 (1) F3A (2) F3A (2) SIE 22NC (1) AES 23 (1) AES S13 (1) AES S21 (1) AES 24 (1) 24V PSU 4W PIN 2 (2) 24V PSU 4W PIN 4 (2) EMERG 6W PIN 1 (1) EMERG 6W PIN 2 (1) EMERG 6W PIN 3 EMERG 6W PIN 4 EMERG 6W PIN 5 (1) EMERG 6W PIN 6 RELEASE COIL 2 (1)

AES X1 (1) F3B (1) F1B (1) F2B (1) SIE A1+ (2) ENG_24V ENG_24V_GND CHASSIS GND ENG_24V NOT USED NOT USED ENG_24V_GND NOT USED ENG_24V 24V PSU 4W PIN 2 (2) 24V PSU 4W PIN 4 (2) SIE 21NC (2) SIE A2M5 (1) RELEASE COIL 1(1) (2)

24

BLACK

24

RED / BLACK

L UXEL P LATESETTER VOLUME 2 (8-63)

8.1.92 EDGE_DETECT (9970-0448)

230mm Label ED PL2 Label STB PL6 20 mm Pin 1 NOTE this view from the wire entry side Pin 2

20 mm

20mm Part number etc Label STB PL3 110mm 40mm

(in centre)

20mm Label ED PL1 30mm

Table 8.83 EDGE_DETECT

AMP CT ED PL1 SIGNALS STB PL3

PIN 1 PIN 2 PIN 3 PIN 4

+5V SIGNAL

PIN 14 PIN 10

0V LINK 0V

PIN 9 PIN 9 TO PIN 5

STB PL6

MOLEX ED PL2

PIN 1 PIN 2

24V SWITCHED 0V

PIN 1 PIN 3

8.1.93 LSB_DATA_VBOMB (9970-0449)

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

Table 8.84 LSB_DATA_VBOMB

26W HD PLUG (SSB) SIGNALS 8W RJ45 (VBOMB SK1)

PIN 1 PIN 6

CHASSIS GND CABLE SCREEN PWCON+

CONNECTOR SHELL PIN 7 TWISTED PAIR WITH PIN 8 THIS CONNECTOR PIN 8 PIN 2 TWISTED PAIR WITH PIN 1 THIS CONNECTOR PIN 4 TWISTED PAIR WITH PIN 3 THIS CONNECTOR

PIN 7 PIN 9

PWCONBSCON-

PIN 10

LD1-

VOLUME 2 (8-64) S YSTEM C ABLING DESCRIPTIONS

Table 8.84 LSB_DATA_VBOMB

PIN 18 PIN 19 PIN 20 BSCON+ LD1+ LD3PIN 1 PIN 3 PIN 6 TWISTED PAIR WITH PIN 5 THIS CONNECTOR PIN 5

PIN 21

LD3+

8.1.94 VBOMB_IHPEN (9970-0450)

Pins down

Label VLD BRD Label VBOMB Label PD BRD 315mm

Pull off loop

120mm 150mm Label Part No etc

Pins up

50mm

Table 8.85 VBOMB_IHPEN

IDC SOCKET SIGNALS HEADER VLD BRD

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16

LASER PRESENT POS +5V ANLG ANLG GND

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5

ANLG GND EDGE DETECT ENABLE BAR ANLG GND DRIVE LEVEL ANLG GND LOW LEVEL ANLG GND BIAS LEVEL ANLG GND ANLG GND ANLG GND

PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14 PIN 15 PIN 16

L UXEL P LATESETTER VOLUME 2 (8-65)

8.1.95 REG_PIN (9970-0451)

Label REGPIN RIGHT Label RPI PL3 50mm 100 mm Part number 520 mm 20 mm 1000 mm pin 1

20mm Label REGPIN LEFT 60 mm

Table 8.86 REG_PIN

AMP CT PL3 SIGNALS

PIN 1 PIN 2 PIN 3 PIN 4

NOT CONNECTED NOT CONNECTED REG PIN LEFT REG PIN RIGHT M4 RING TERMINAL M4 RING TERMINAL

8.1.96 REG_FHMB (9970-0452)

Label FHMB4 PL25 Label RPI PL2 20 mm pin 1 75 mm Part number 400mm 20 mm

Table 8.87 REG_FHMB

AMP CT FHMB4 PL25 SIGNALS MOLEX RPI PL2

PIN 1 PIN 2 PIN 3 PIN 4

NOT CONNECTED +5V 0V REG PIN SIGNAL PIN 1 PIN 2 PIN 3

VOLUME 2 (8-66) S YSTEM C ABLING DESCRIPTIONS

8.1.97 COMP_PANEL (9970-0453)

COMP 1 GREEN / YELLOW RING TERM M4 110 mm COMP 2 GREEN / YELLOW RING TERM M4 180 mm Cable 2 RING TERM M5 Cable 1 RING TERM M5

FASTON

GREEN / YELLOW RING TERM M5 420 mm Cable 3

PIGGY BACK FASTON

BROWN 400 mm Cable 4

FUSE 1

BROWN FASTON 360 mm Place PART number / Cable 1, 2 3 etc label in the centre of each cable Cable 5

FUSE 2

8.1.98 COMP_MAINS (9970-0454)

Label REL 9 30mm from end Tie wrap 120mm apart 60 mm 240 mm BLUE 4.3 m 200 mm part number etc Label Compressors

BROWN

GN/YL

100 mm

Label REL 7 30mm from end

View from connection side

Label CHASSIS

8.1.99 ILOCK_COMP (99700-455)

Label REL 9 30mm from end Tie wrap 120mm apart 60 mm 240 mm BLUE 4.3 m 200 mm part number etc Label Compressors

BROWN

GN/YL

100 mm

Label REL 7 30mm from end

View from connection side

Label CHASSIS

L UXEL P LATESETTER VOLUME 2 (8-67)

8.1.100 ILOCK_CTRL (9970-0456)

Label COMP Label REL A Fastons 40 mm 300 mm Label PUMP CTRL Label REL B

10 mm

150 mm 50 mm

Label REL A Fastons

Label PUMP 100 mm tie wrap Label CHASSIS M5

40 mm

Label REL B

Table 8.88 ILOCK_CTRL

8 WAY MOLEX SIGNALS

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8

CHASSIS PUMP REL A

M5 FASTON TWIST WITH PIN 6

COMP REL A

FASTON TWIST WITH PIN 8

PUMP REL B

FASTON

COMP REL B

FASTON

8.1.101 SOL_CTRL (9970-0457)

L a b el L a b el L a b el La b e l La b e l La b e l M IX M IX M IX M IX M IX M IX R EL R EL R EL REL REL REL A 7 4 B 6 9 50 m m

100 m m 600 m m

L a b el M IX FA N

50 m m 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 50 m m P a rt N o etc 40 m m L a b el A LE R T R E L C O IL B 430 m m L a b el FH M B 1 P L2 3

Table 8.89 SOL_CTRL

FHMB1 PL1 8 WAY SIGNALS

PIN 1 PIN 2 PIN 3 PIN 4

SPARE SPARE SPARE SPARE

VOLUME 2 (8-68) S YSTEM C ABLING DESCRIPTIONS

Table 8.89 SOL_CTRL

PIN 5 PIN 6 PIN 7 MIXER FAN MIXER FAN RTN ALERT COIL A FASTON MIX REL A FASTON MIX REL B FASTON ALERT REL COIL A T/PAIR WITH ALERT REL COIL B FASTON ALERT REL COIL B T/PAIR WITH MIX REL B YELLOW BLACK BLUE

PIN 8 FHMB1 PL2 2 WAY PIN 1 PIN 2 MIXER FAN 6 WAY PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6

ALERT COIL B

BLACK

+24V RTN

FASTON MIX REL 4 T/PAIR WITH MIX REL 6 FASTON MIX REL 6

WH/OR BLACK

SPARE +24V FAN DETECT SPARE 24V RTN FAN DETECT RTN FASTON MIX REL 9 PL23 PIN 4 BLACK WHITE FASTON MIX REL 7 T/PAIR WITH MIX REL 9 PL23 PIN 3 T/PAIR WITH PL23 PIN 4 WH/OR GREEN

8.1.102 RIB3 (9970-0458)

4 20 m m

80 m m

L abel I N P U T D IS T P L 5

L abel FH M B P O S 1 P L 1 8 And p art nu mber

V iew fro m n o n co n n ectio n sid e

8.1.103 ENG_S1/2 (9970-0459)

Label S2
Label INPUT DIST PL3 60 mm

300 mm

1000 mm Label S1 1020 mm

60 mm Label INPUT DIST PL4

Part No etc

Tie wrap every 100mm

Table 8.90 ENG_S1/2

AMP CT SIGNALS AMP CT

PL4 PIN 1 PL4 PIN 2 PL4 PIN 3

LE PLATE IN INPUT NIP PUL_GND LE PLATE IN INPUT NIP SUPPLY LE PLATE IN INPUT NIP GROUND

S1 S1 S1

PIN 1 TWISTED PAIR WITH S1 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S1 PIN 4

L UXEL P LATESETTER VOLUME 2 (8-69)

Table 8.90 ENG_S1/2

PL4 PIN 4 PL3 PIN 1 PL3 PIN 2 PL3 PIN 3 PL3 PIN 4 LE PLATE IN INPUT NIP SIGNAL TE PLATE PAST PUSH BAR PUL_GND TE PLATE PAST PUSH BAR SUPPLY TE PLATE PAST PUSH BAR GROUND TE PLATE PAST PUSH BAR SIGNAL S1 S2 S2 S2 S2 PIN 4 PIN 1 TWISTED PAIR WITH S1 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S1 PIN 4 PIN 4

8.1.104 VAC (9970-0460)

Lable BV31 Sol 25mm

100mm Lable FHMB4 PL1

1175 mm

Label I/LOCK BOX VAC PUMP Label FHMB4 PL8 160mm Part number and issue

Table 8.91 VAC

8 WAY MOLEX PL1 SIGNALS I/LOCK BOX VAC PUMP

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 FHMB4 PL8 PIN 1 PIN 2 PIN 3 BV31 SOL PIN 1 PIN 2

SPARE SPARE PUMP RELAY PUMP RELAY RTN SPARE SPARE SPARE 8 W MOLEX PIN 2 8 W MOLEX PIN 6 BLUE BLACK ( TWIST PAIR PIN 2)

NOT USED COMP RELAY COMP RELAY RTN 8 W MOLEX PIN 4 8 W MOLEX PIN 8 ( 2 WIRES IN PIN 4) (2 WIRES IN PIN 8) RED BLACK ( TWIST PAIR PIN 4)

COMP RELAY COMP RELAY RTN

8 W MOLEX PIN 4 8 W MOLEX PIN 8

RED BLACK ( TWIST PAIR PIN 4)

VOLUME 2 (8-70) S YSTEM C ABLING DESCRIPTIONS

8.1.105 ENG_M6 (9970-0461)

1160 mm Label M6 100mm Part No etc
AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT WIRE COLOUR

Label FHMB4 PL15

PL15 PIN 1 PL15 PIN 3 PL15 PIN 2

NOT USED DC_MOT_A DC_MOT_B

M6 PIN 1 M6 PIN 2 M6 PIN 3 RED BLACK TP WITH M6 PIN 3

8.1.106 ENG_M38 (9970-0462)

1600 mm Label FHMB1 PL27 Label M38 100mm Part No etc
JST 6WAY SIGNALS JST 6WAY + ADAPTER WIRE COLOUR

PL27 PIN 1 PL27 PIN 2 PL27 PIN 3 PL27 PIN 4 PL27 PIN 5 PL27 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

M38 PIN 6 M38 PIN 5 M38 PIN 4 M38 PIN 3 M38 PIN 2 M38 PIN 1

TWIST WITH M38 PIN 2 TWIST WITH M38 PIN 1 TWIST WITH M38 PIN 3

8.1.107 ENG_S118 (9970-0463)

Label FHMB4 PL23 pin 1
100mm Part No etc

pin 1 Label S118

1700 mm

Table 8.92 ENG_S118

AMP CT SIGNALS AMP CT

PIN 1 PIN 2 PIN 3 PIN 4

PLATE ON PLATERN PUL_GND PLATE ON PLATERN SUPPLY PLATE ON PLATERN GROUND PLATE ON PLATERN GND SIGNAL

S118 S118 S118 S118

PIN 1 TWISTED PAIR WITH PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH PIN 4 PIN 4

L UXEL P LATESETTER VOLUME 2 (8-71)

8.1.108 ENG_M10 (9970-0464)

740 mm Label M10 Part No etc 100mm Label FHMB1 PL28

Table 8.93 ENG_M10

JST 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR

PL28 PIN 1 PL28 PIN 2 PL28 PIN 3 PL28 PIN 4 PL28 PIN 5 PL28 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

M10 PIN 6 M10 PIN 5 M10 PIN 4 M10 PIN 3 M10 PIN 2 M10 PIN 1

TWIST WITH M10 PIN 2 TWIST WITH M10 PIN 1 TWIST WITH M10 PIN 3

8.1.109 ENG_M11 (9970-0465)

2300 mm Label M11 100mm Part No etc Label FHMB1 PL30

Table 8.94 ENG_M11

JST 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR

PL30 PIN 1 PL30 PIN 2 PL30 PIN 3 PL30 PIN 4 PL30 PIN 5 PL30 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

M11 PIN 6 M11 PIN 5 M11 PIN 4 M11 PIN 3 M11 PIN 2 M11 PIN 1

TWIST WITH M11 PIN 2 TWIST WITH M11 PIN 1 TWIST WITH M11 PIN 3

8.1.110 ENG_S114/116/113 (9970-0466)

L ab el FH M B 1 P L1 4 60 m m 150 m m L ab el S 1 1 3
15 0mm 1 50 mm

1080 m m 180 m m L ab el FH M B 1 P L2 5

Lab el S 1 1 6

6 30 mm

130 m m Lab el S 1 1 4 L

35 0m m

590 m m L ab el P art N o etc P lace 7 0 m m from ju n ctio n

Lab el D IS T I/P P L1 0

L ab el S 1 1 4 R

VOLUME 2 (8-72) S YSTEM C ABLING DESCRIPTIONS

Table 8.95 ENG_S114/116/113

AMP CT SIGNALS AMP EI

PL25 PIN 1 PL25 PIN 2 PL25 PIN 3 PL25 PIN 4 PL10 PIN 1 PL10 PIN 2 PL10 PIN 3 PL10 PIN 4 PL14 PIN 1 PL14 PIN 2 PL14 PIN 3 PL14 PIN 4 PL14 PIN 5 PL14 PIN 6 PL14 PIN 7 PL14 PIN 8

NOT USED PLATE PUSHER HOME SUPPLY PLATE PUSHER HOME GROUND PLATE PUSHER HOME NOT USED CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL S113 S113 S113 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S10 PIN 2 SIGNAL S116 S116 S116 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S10 PIN 2

CENTERING CONTINUITY GROUND CENTERING CONTINUITY SIGNAL

S114R TWISTED PAIR WITH S114L S114L

8.1.111 ENG_M3/5 (9970-0467)

140 mm Label M5 Label M3 420 mm Part No etc Tie wraps every 100mm 30 mm 70 mm 900 mm Label FHMB4 PL16 Label FHMB4 PL27

Table 8.96 ENG_M3/5

AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT WIRE COLOUR

PL16 PIN 1 PL16 PIN 3 PL16 PIN 2 JST 6 WAY PL27 PIN 1 PL27 PIN 2 PL27 PIN 3 PL27 PIN 4 PL27 PIN 5 PL27 PIN 6

NOT USED DC_MOT_A DC_MOT_B

M5 PIN 1 M5 PIN 2 M5 PIN 3 JST + ADAPTOR RED BLACK TP WITH M5 PIN 3

OUT A OUT C +24V +24V OUT B OUT D

M3 PIN 6 M3 PIN 5 M3 PIN 4 M3 PIN 3 M3 PIN 2 M3 PIN 1

TWIST WITH M3 PIN 2 TWIST WITH M3 PIN 1 TWIST WITH M3 PIN 3

L UXEL P LATESETTER VOLUME 2 (8-73)

8.1.112 ENG_M36/37 (9970-0468)

Label M 37 m 300 m 850 m m 40 m m Label FH B4 PL22 M Tie w every raps 100m m Part N etc o 40 m m Label FH B4 PL20 M

880 m m Label M 36

Table 8.97 ENG_M36/37

AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT WIRE COLOUR

PL20 PIN 1 PL20 PIN 3 PL20 PIN 2 PL22 PIN 1 PL22 PIN 3 PL22 PIN 2

NOT USED DC_MOT_A DC_MOT_B NOT USED DC_MOT_A DC_MOT_B

M37 PIN 1 M37 PIN 2 M37 PIN 3 M36 PIN 1 M36 PIN 2 M36 PIN 3 RED TP WITH M36 PIN 3 BLACK RED TP WITH M37 PIN 3 BLACK

8.1.113 INV_MOT (9970-0471)

M5 Label MOT_GND Label MOT_V1 M4 Label MOT_U1 M4
100 mm 110 mm

M5 60 mm

M5 120 mm

Label SCREEN (x2) Cable Gland 530 mm 40 mm Label SIE 1L1 Label SIE 3L2 Label SIE 5L3 M5 120 mm Label GND

110 mm

Cable 1 and part number in middle of cable

100 mm

Label MOT_W1 M4

Table 8.98 INV_MOT

CONNECTOR MOTOR SIGNAL CABLE COLOUR

MOT_V1 MOT_U1 MOT_W1 SCREEN MOT_GND

M4 M4 M4 M5 M5

SIE 1L1 SIE 3L2 SIE 5L3 SCREEN GND

BLADE BLADE BLADE M5 M5

BLUE BROWN WHITE BLACK GN/YL

VOLUME 2 (8-74) S YSTEM C ABLING DESCRIPTIONS

M4 Label INV GND Label INV U/T1 Label INV V/T2 M4 145 mm
60 mm 40 mm

M5 145 mm

Label SCREEN (x2) 40 mm 110 mm Label SIE 2T1 Label SIE 4T2 Label SIE 6T3 M5 145 mm Label GND

40 mm 40 mm

Cable 2 and part number in middle of cable

Label INV W/T3

Table 8.99 INV_MOT

CONNECTOR MOTOR SIGNAL CABLE COLOUR

INV U/T1 INV V/T2 INV W/T3 SCREEN INV GND

M4 FORK M4 FORK M4 FORK M4 M4

SIE 2T1 SIE 4T2 SIE 6T3 SCREEN GND

BLADE BLADE BLADE M5 M5

BLUE BROWN WHITE BLACK GN/YL

8.1.114 VBOMB_FAN (9970-0472)

170 mm

Label FAN (near to connector)

Label Part Number etc (in the center)

Label VB OM B PL12 (near to connector)

Table 8.100 VBOMB_FAN

FAN SIGNALS VBOMB PL12 WIRE COLOUR

PIN 1 PIN 2 PIN 3

FAN FAIL FAN 24V FAN 0V

PIN 2 PIN 1 PIN 3

YELLOW RED BLACK

8.1.115 CAN_FHMB1_4 (9970-0473)

Label FHMB4 SK1 pin 1

30mm

Label FHMB 1 SK3 pin 1

30mm 100mm Part No etc

1000 mm

L UXEL P LATESETTER VOLUME 2 (8-75)

Table 8.101 CAN_FHMB1_4

15 D TYPE PLG SIGNAL 15 D TYPE PLG COLOUR COMENTS

PIN 1 PIN2

CHASSIS GND CAN GND

PIN 1 PIN2 BLACK / RED BLACK / WHITE

CONNECT SCREEN (TWISTED PAIR WITH PIN 3)

PIN 3

CAN +5V

PIN 3

RED / BLACK WHITE / BLACK

PIN 4 PIN 5 PIN 6 PIN 7 PIN 8

CAN CAN + RESET RESET + INDEX-

PIN 4 PIN 5 PIN 6 PIN 7 PIN 8

BLACK / GREEN GREEN / BLACK BLACK / YELLOW YELLOW / BLACK BLACK / ORANGE ORANGE / BLACK

(TWISTED PAIR WITH PIN 5)

(TWISTED PAIR WITH PIN 7)

(TWISTED PAIR WITH PIN 9)

PIN 9

INDEX +

PIN 9

PIN 10 PIN 11

NO CONNECTION E_CLK-

PIN 10 PIN 11 BLACK / BLUE

( (TWISTED PAIR WITH PIN 12)

PIN 12 PIN 13

E_CLK+ 0V

PIN 12 PIN 13

BLUE / BLACK BLACK / BROWN (TWISTED PAIR WITH PIN 14)

PIN 14 PIN 15

CAN_SIG_RTN NO CONNECTION

PIN 14 PIN 15

BROWN / BLACK

8.1.116 PUMP (9970-0479)

Label CB BROWN BLUE
80 mm 220 mm 620 mm

BROWN

BLUE
30 mm

GREEN/YELLOW Label I/LOCK PUMP

100 mm

Label REL 7

Label CHASSIS

GREEN/YELLOW Suppliers part number etc in centre

Label PUMP OUTLET

VOLUME 2 (8-76) S YSTEM C ABLING DESCRIPTIONS

8.1.117 ENG_FHMB_PWR (99700480)

Label I/LOCK BOX PWR 1 pin 1 100 mm 1230 mm Part no. here 70mm 150mm Label I/LOCK BOX EMERG pin 1 Label FHMB1 PL31 pin 1

70mm

Table 8.102 ENG_FHMB_PWR

MOLEX (10W) I/ LOCK BOX PWR 1 SIGNAL MOLEX (8W) FHMB1 PL31 WIRE COLOUR COMMENTS

PIN 1

CHASSIS GND +24V

PL31 PIN 1

BLACK

SCREEN

PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10

PL31 PIN 2

WHITE/ORANGE

TWIST FHMB PL31 PIN 6

24V GROUND

PL31 PIN 6

BLACK

8.1.118 ILOCK_LINK (99700481)

Table 8.103 ILOCK_LINK
MOLEX (10W) PTM PANEL SIGNAL LOOPBACK

PIN 1 PIN 2 PIN 3 PIN 4 INTERLOCK RELAY EODD INTERLOCK RETURN PIN 7 PIN 8

PIN 5 PIN 6 PIN 7 INTERLOCK RELAY RETURN EODD INTERLOCK PIN 3

PIN 8 PIN 9 PIN 10

PIN 4

L UXEL P LATESETTER VOLUME 2 (8-77)

8.1.119 BUFF_LINK (9970-0482)

Table 8.104 BUFF_LINK
MOLEX (10W) PTM PANEL SIGNAL LOOPBACK

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 INTERLOCK RELAY RETURN EODD INTERLOCK PIN 3 PIN 4 INTERLOCK RELAY EODD INTERLOCK RETURN PIN 7 PIN 8

8.1.120 ENGB1_S118 (9970-0490)

Label FHMB4 PL23 pin 1
100mm Part No etc

pin 1 Label S118

1960 mm

Table 8.105 ENGB1_S118

AMP CT SIGNALS AMP CT

PIN 1 PIN 2 PIN 3 PIN 4

PLATE ON PLATERN PUL_GND PLATE ON PLATERN SUPPLY PLATE ON PLATERN GROUND PLATE ON PLATERN GND SIGNAL

S118 S118 S118 S118

PIN 1 TWISTED PAIR WITH PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH PIN 4 PIN 4

8.1.121 ENGB1_M10 (9970-0491)

800mm Label M10 Part No etc 100mm Label FHMB1 PL28

Table 8.106 ENGB1_M10

JST 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR

PL28 PIN 1 PL28 PIN 2 PL28 PIN 3 PL28 PIN 4 PL28 PIN 5

OUT A OUT C +24V +24V OUT B

M10 PIN 6 M10 PIN 5 M10 PIN 4 M10 PIN 3 M10 PIN 2

TWIST WITH M10 PIN 2 TWIST WITH M10 PIN 1 TWIST WITH M10 PIN 3

VOLUME 2 (8-78) S YSTEM C ABLING DESCRIPTIONS

Table 8.106 ENGB1_M10

PL28 PIN 6 OUT D M10 PIN 1

8.1.122 ENGB1_S1/S2 (9970-0492)

Label S2
Label INPUT DIST PL3 60 mm

500 mm

900 mm Label S1 1260 mm

60 mm Label INPUT DIST PL4

Part No etc

Tie wrap every 100mm

Table 8.107 ENGB1_S1/S2

AMP CT SIGNALS AMP CT

PL4 PIN 1 PL4 PIN 2 PL4 PIN 3 PL4 PIN 4 PL3 PIN 1 PL3 PIN 2 PL3 PIN 3 PL3 PIN 4

LE PLATE IN INPUT NIP PUL_GND LE PLATE IN INPUT NIP SUPPLY LE PLATE IN INPUT NIP GROUND LE PLATE IN INPUT NIP SIGNAL TE PLATE PAST PUSH BAR PUL_GND TE PLATE PAST PUSH BAR SUPPLY TE PLATE PAST PUSH BAR GROUND TE PLATE PAST PUSH BAR SIGNAL

S1 S1 S1 S1 S2 S2 S2 S2

PIN 1 TWISTED PAIR WITH S1 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S1 PIN 4 PIN 4 PIN 1 TWISTED PAIR WITH S1 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S1 PIN 4 PIN 4

8.1.123 ILOCK_LINK (9970-0493)

Table 8.108 ILOCK_LINK
MOLEX (10W) PTM PANEL SIGNAL LOOPBACK

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 INTERLOCK RELAY RETURN EODD INTERLOCK PIN 3 PIN 4 INTERLOCK RELAY EODD INTERLOCK RETURN PIN 7 PIN 8

L UXEL P LATESETTER VOLUME 2 (8-79)

8.1.124 ENGB1_M11 (9970-0494)

2800 mm Label M11 100mm 600 mm Part No etc Label FHMB1 PL30

Table 8.109 ENGB1_M11

JST 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR

PL30 PIN 1 PL30 PIN 2 PL30 PIN 3 PL30 PIN 4 PL30 PIN 5 PL30 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

M11 PIN 6 M11 PIN 5 M11 PIN 4 M11 PIN 3 M11 PIN 2 M11 PIN 1

TWIST WITH M11 PIN 2 TWIST WITH M11 PIN 1 TWIST WITH M11 PIN 3

8.1.125 ENGB1_S114/116/113 (9970-0495)

L ab el F H M B 1 PL 1 4 1 30 m m 2 70 m m L abel S1 13
1 00 m m 40 0m m

2 40 m m 8 00 m m

L ab el FH M B 1 PL 25

50 m m 60 0 m m
4 00 m m

L ab el D IS T I/P PL 10 50 m m 2 cab le ties L abel I/P D IS T PL 12

L abel S1 16

90 0m m

13 0 m m L abel S 11 4L

L ab el Part N o etc Place 7 0m m fro m jun ction

L ab el S 11 4R

Table 8.110 ENGB1_S114/116/113

AMP CT SIGNALS AMP EI

PL25 PIN 1 PL25 PIN 2 PL25 PIN 3 PL25 PIN 4

NOT USED PLATE PUSHER HOME SUPPLY PLATE PUSHER HOME GROUND PLATE PUSHER HOME SIGNAL S116 S116 S116 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S10 PIN

PL10 PIN 1 PL10 PIN 2 PL10 PIN 3 PL10 PIN 4

NOT USED CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL S113 S113 S113 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S10 PIN

PL14 PIN 1

VOLUME 2 (8-80) S YSTEM C ABLING DESCRIPTIONS

Table 8.110 ENGB1_S114/116/113

PL14 PIN 2 PL14 PIN 3 CENTERING CONTINUITY GROUND S114R TWISTED PAIR WITH S114L

8.1.126 ENG_1BHP_S3/S10/S14 (9970-0497)

Label DIST O/P PL9 Label DIST O/P PL7
120mm

Label DIST O/P PL10 Label DIST O/P PL11 Label DIST O/P PL12

Label DIST O/P PL6

Label S10 Label S11 Cover this single wire with cable wrap 420mm 730 mm 80mm 120mm Label S12
note 1 note 1

Label 24V DIST O/P PL2

Label S3

140mm

note 2 267mm long 80 mm Label S13

300 mm

Part number here

Label Punch Frame

Label S14 90 mm 300mm 100 mm

note 2 267mm long 1170mm 240 mm

400 mm Cover this single wire with cable wrap 700mm S12 680mm S13 All others 30mm

Wire with cable wrap free to move within the chain

Chain must be able to bend in this direction.

note 1. This end piece has the holes for the links note 2. This end piece has the pins for the links
8mm

Rad 10mm. 10mm pitch.

Labels to be position as shown from their connector

Table 8.111 ENG_1BHP_S3/S10/S14

AMP CT SIGNALS AMP EI

PL6 PIN 1 PL6 PIN 2 PL6 PIN 3 PL6 PIN 4

NOT USED REG MOTOR OUT SUPPLY REG MOTOR OUT GROUND REG MOTOR OUT SIGNAL S10 S10 S10 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S14 PIN

PL7 PIN 1 PL7 PIN 2 PL7 PIN 3 PL7 PIN 4

NOT USED CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL S14 S14 S14 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S14 PIN

PL9 PIN 1 PL9 PIN 2 PL9 PIN 3 PL9 PIN 4

NOT USED REG MOTOR IN SUPPLY REG MOTOR IN GROUND REG MOTOR IN SIGNAL S11 S11 S11 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S14 PIN

PL10 PIN 1 PL10 PIN 2

NOT USED NOT USED

L UXEL P LATESETTER VOLUME 2 (8-81)

Table 8.111 ENG_1BHP_S3/S10/S14

PL10 PIN 3 PL10 PIN 4 PL11 PIN 1 PL11 PIN 2 PL11 PIN 3 PL11 PIN 4 PL2 PIN 1 PL2 PIN 2 PL2 PIN 3 PL2 PIN 4 PL12 PIN 1 PL12 PIN 2 PL12 PIN 3 CAN ID GND LINK TO PL 12 PIN 3 CENTERING RH DETECT GROUND CENTERING RH DETECT SIGNAL NOT USED NOT USED CENTERING LH DETECT GROUND CENTERING LH DETECT SIGNAL DETECT LE PUNCH PUL GND DETECT LE PUNCH SUPPLY DETECT LE PUNCH GROUND DETECT LE PUNCH SIGNAL PUNCH FRAME M4 RING TAG PUNCH FRAME M4 RING TAG S12 (DRAG CHAIN ASSY)

S13 (DRAG CHAIN ASSY) S3 S3 S3 S3 PIN 1 TWISTED PAIR WITH S3 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S3 PIN 4 PIN 4

8.1.127 ENG_IHP_M3/5 (9970-0498)

Label M3 50 mm 1150 mm 140 mm Label FHMB4 PL27

Label M5 50 mm

450 mm 600 mm Part No etc Tie wraps every 100mm

Label FHMB4 PL16

Table 8.112 ENG_IHP_M3/5

AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT WIRE COLOUR

PL16 PIN 1 PL16 PIN 2 PL16 PIN 3 JST 6 WAY PL27 PIN 1 PL27 PIN 2 PL27 PIN 3 PL27 PIN 4 PL27 PIN 5 PL27 PIN 6

NOT USED DC_MOT_A DC_MOT_B

M5 PIN 1 M5 PIN 2 M5 PIN 3 JST + ADAPTOR RED BLACK TP WITH M5 PIN 3

OUT A OUT C +24V +24V OUT B OUT D

M3 PIN 1 M3 PIN 2 M3 PIN 3 M3 PIN 4 M3 PIN 5 M3 PIN 6 TWIST WITH M3 PIN 3 TWIST WITH M3 PIN 1 TWIST WITH M3 PIN 2

VOLUME 2 (8-82) S YSTEM C ABLING DESCRIPTIONS

8.1.128 ENG_FPD_S21 (9970-0499)

Label FHMB4 PL4 1240 mm Label PHOTO DETECT

200 mm

Part Number

Table 8.113 ENG_FPD_S21

3 WAY AMP CT SIGNALS MOLEX 22-01-2045

PIN 1 PIN 2 PIN 3

CATHODE ANODE SCREEN

PIN 2 (TWISTED WITH MOLEX PIN 1) PIN 1

8.1.129 MAN_STOP (9970-0500)

EMERG SWITCH Label I/LOCK BOX EMERG pin 1 150mm 450mm 50mm Part no. here

Table 8.114 MAN_STOP

MOLEX (6W) I/LOCK BOX EMERG SIGNAL M4 FORK WIRE COLOUR COMMENTS

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 24V GND EMERG M4 FORK WHITE/ORANGE +24V EMERG M4 FORK WHITE/ORANGE TWISTED PAIR

8.1.130 SEMI_S109/110 (9970-0501)

65 m m L ab el S 1 1 0 720 m m L ab el FH M B 4 P L9

Lab el S 1 0 9

150 m m

T ie w rap s ev ery 100m m Lab el Part N o etc Place 7 0 m m fro m co n n ector

L UXEL P LATESETTER VOLUME 2 (8-83)

Table 8.115 SEMI_S109/110

AMP CT SIGNALS AMP EI

PL9 PIN 1 PL9 PIN 2 PL9 PIN 3 PL9 PIN 4 PL9 PIN 5 PL9 PIN 6 PL9 PIN 7 PL9 PIN 8

NOT USED SWING ROLLER HOME SUPPLY SWING ROLLER HOME GROUND SWING ROLLER HOME SIGNAL NOT USED SWING ROLLER IN DRUM SUPPLY SWING ROLLER IN DRUM GROUND SWING ROLLER IN DRUM SIGNAL S110 S110 S110 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S110 PIN 2 S109 S109 S109 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S109 PIN 2

8.1.131 SEMI_M36/37 (9970-0502)

L abel M 37 300 m m 850 m m 40 m m 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 40 m m L abel F H M B 4 P L20

880 m m L abel M 36

Table 8.116 SEMI_M36/37

AMP CT 3WAY SIGNALS 3 WAY MOLEX MINIFIT WIRE COLOUR

PL20 PIN 1 PL20 PIN 2 PL20 PIN 3 PL22 PIN 1 PL22 PIN 3 PL22 PIN 2

NOT USED DC_MOT_A DC_MOT_B NOT USED DC_MOT_A DC_MOT_B

M37 PIN 1 M37 PIN 2 M37 PIN 3 M36 PIN 1 M36 PIN 2 M36 PIN 3 RED BLACK TP WITH M36 PIN 3 RED BLACK TP WITH M37 PIN 3

8.1.132 BV41PUNCH_LINK (9970-0503)

100MM LABEL 24VDIST PL1

40MM
LABEL 24VDIST PL4

LABEL part no etc

C bl Ti h

Table 8.117 BV41PUNCH_LINK

AMP CT PL1 SIGNAL LOOPBACK

PIN 1

VOLUME 2 (8-84) S YSTEM C ABLING DESCRIPTIONS

Table 8.117 BV41PUNCH_LINK

PIN 2 PIN 3 PIN 4 AMP CT PL4 PIN 1 PIN 2 PIN 3 PIN 4 DIG GND SENSOR INPUT CONNECT TO PL4 PIN 4 DIG GND SENSOR INPUT CONNECT TO PL1 PIN 4

8.1.133 BV41WEB_LINK (9970-0504)

LABEL DIST PL6

40MM
LABEL DIST PL9

LABEL part no etc

Cable Tie here

Table 8.118 BV41WEB_LINK

AMP CT PL6 SIGNAL LOOPBACK

PIN 1 PIN 2 PIN 3 PIN 4

AMP CT PL9

DIG GND SENSOR INPUT

CONNECT TO PL6 PIN 4

PIN 1 PIN 2 PIN 3 PIN 4 DIG GND SENSOR INPUT CONNECT TO PL9 PIN 4

8.1.134 EXT_M11 (9970-0505)

Label FHMB1 PL30 850 mm 100mm Part No etc Label EXTEN M11

L UXEL P LATESETTER VOLUME 2 (8-85)

Table 8.119 EXT_M11

JST 6WAY SIGNALS MOLEX 6WAY WIRE COLOUR

FHMB1 PL30 PIN 1 FHMB1 PL30 PIN 2 FHMB1 PL30 PIN 3 FHMB1 PL30 PIN 4 FHMB1 PL30 PIN 5 FHMB1 PL30 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

EXTEN M11 PIN 1 EXTEN M11 PIN 2 EXTEN M11 PIN 3 EXTEN M11 PIN 4 EXTEN M11 PIN 5 EXTEN M11 PIN 6

TWIST WITH M11 PIN 5 TWIST WITH M11 PIN 6 TWIST WITH M11 PIN 4

8.1.135 FRONT_SENSOR_EXT (9970-0506)

Lab el FH M B 1 P L1 4 130 m m 240 m m 100 m m Lab el Sen sor E x ten sio n 6 00 m m 50 m m 50 m m L ab el D IST I/P PL 1 Lab el FH M B 1 P L2 5

L ab el P art N o etc P lace 7 0 m m from ju n ctio n

1000 m m

2 cab le ties

Lab el I/P D IST PL 1 2 L ab el FH M B 4 PL 2 3

Table 8.120 FRONT_SENSOR_EXT

AMP CT SIGNALS MOLEX

PL25 PIN 1 PL25 PIN 2 PL25 PIN 3 PL25 PIN 4 PL10 PIN 1 PL10 PIN 2 PL10 PIN 3 PL10 PIN 4 PL14 PIN 1 PL14 PIN 2 PL14 PIN 3 PL14 PIN 4 PL14 PIN 5 PL14 PIN 6 PL14 PIN 7 PL14 PIN 8 PL23 PIN 1 PL23 PIN 2

NOT USED PLATE PUSHER HOME SUPPLY PLATE PUSHER HOME GROUND PLATE PUSHER HOME NOT USED CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL SENSOR EXT PIN 4 SENSOR EXT PIN 5 TP WITH PIN 3 SENSOR EXT PIN 6 SIGNAL SENSOR EXT PIN 1 SENSOR EXT PIN 2 TP WITH PIN 3 SENSOR EXT PIN 3

CENTERING CONTINUITY GROUND CENTERING CONTINUITY SIGNAL

SENSOR EXT PIN 11 TP WITH TP 12 SENSOR EXT PIN 12

PLATE ON PLATERN PUL_GND PLATE ON PLATERN SUPPLY

SENSOR EXT PIN 7 TP WITH PIN 8 SENSOR EXT PIN 8

VOLUME 2 (8-86) S YSTEM C ABLING DESCRIPTIONS

Table 8.120 FRONT_SENSOR_EXT

PL23 PIN 3 PL23 PIN 4 PL12 PIN 1 PL12 PIN 2 PL12 PIN 3 CAN ID GND LINK TO PL 12 PIN 3 PLATE ON PLATERNGROUND PLATE ON PLATERN GND SUPPLY SENSOR EXT PIN 9 TP WITH PIN 10 SENSOR EXT PIN 10

8.1.136 B1_FRONTSENSOR (9970-0507)

Lab el S1 1 8 1 9 0m m

Lab el S1 1 3 270 m m
10 0m m 40 0m m

900 m m Lab el Sen sor E x ten sio n

Lab el S1 1 6

130 m m

90 0m m

4 00 mm

Lab el S1 1 4 L Lab el S1 1 4 R

Lab el P art N o etc Place 7 0 m m from ju n ction

Table 8.121 B1_FRONTSENSOR

MOLEX SIGNALS AMP

SENSOR EXT PIN 1 SENSOR EXT PIN 2 SENSOR EXT PIN 3 SENSOR EXT PIN 4 SENSOR EXT PIN 5 SENSOR EXT PIN 6 SENSOR EXT PIN 7 SENSOR EXT PIN 8 SENSOR EXT PIN 9 SENSOR EXT PIN 10 SENSOR EXT PIN 11

PLATE PUSHER HOME SUPPLY PLATE PUSHER HOME GROUND PLATE PUSHER HOME SIGNAL

S116 S116 S116 S113 S113 S113 S118 S118 S118 S118

PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S116 PIN 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S113 PIN 2 PIN 1 TWISTED PAIR WITH S118 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S118 PIN 4 PIN 4

CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL PLATE ON PLATERN PUL_GND PLATE ON PLATERN SUPPLY PLATE ON PLATERN GROUND PLATE ON PLATERNGND SIGNAL CENTERING CONTINUITY GROUND CENTERING CONTINUITY SIGNAL

S114R TWISTED PAIR WITH S114L

SENSOR EXT PIN 12

S114L

L UXEL P LATESETTER VOLUME 2 (8-87)

8.1.137 B2_FRONTSENSOR (9970-0508)

L ab el S 1 1 8 150m m

Lab el S1 1 3 150 m m
15 0m m 15 0m m

900 m m Lab el Sen sor E x ten sio n

Lab el S1 1 6

130 m m

63 0m m

3 50 mm

Lab el S1 1 4 L Lab el S1 1 4 R

Lab el P art N o etc Place 7 0 m m from ju n ction

Table 8.122 B2_FRONTSENSOR

MOLEX SIGNALS AMP

SENSOR EXT PIN 1 SENSOR EXT PIN 2 SENSOR EXT PIN 3 SENSOR EXT PIN 4 SENSOR EXT PIN 5 SENSOR EXT PIN 6 SENSOR EXT PIN 7 SENSOR EXT PIN 8 SENSOR EXT PIN 9 SENSOR EXT PIN 10 SENSOR EXT PIN 11 SENSOR EXT PIN 12

PLATE PUSHER HOME SUPPLY PLATE PUSHER HOME GROUND PLATE PUSHER HOME SIGNAL

S116 S116 S116 S113 S113 S113 S118 S118 S118 S118

PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S116 PIN 2 PIN 1 PIN 2 PIN 3 TWISTED PAIR WITH S113 PIN 2 PIN 1 TWISTED PAIR WITH S118 PIN 2 PIN 2 PIN 3 TWISTED PAIR WITH S118 PIN 4 PIN 4

CENTERING HOME SUPPLY CENTERING HOME GROUND CENTERING HOME SIGNAL PLATE ON PLATERN PUL_GND PLATE ON PLATERN SUPPLY PLATE ON PLATERN GROUND PLATE ON PLATERNGND SIGNAL CENTERING CONTINUITY GROUND CENTERING CONTINUITY SIGNAL

S114R TWISTED PAIR WITH S114L S114L

8.1.138 B2_M11 (9970-0509)

1700 mm Label M11 100mm Part No etc Label EXTEN M11

Table 8.123 B2_M11

MOLEX 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR

EXTENM11 PIN 1 EXTENM11 PIN 2 EXTENM11 PIN 3 EXTENM11 PIN 4 EXTENM11 PIN 5 EXTENM11 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

M11 PIN 6 M11 PIN 5 M11 PIN 4 M11 PIN 3 M11 PIN 2 M11 PIN 1

TWIST WITH M11 PIN 2 TWIST WITH M11 PIN 1 TWIST WITH M11 PIN 3

VOLUME 2 (8-88) S YSTEM C ABLING DESCRIPTIONS

8.1.139 B1_M11 (9970-0510)

2000 mm Label M11 100mm 600 mm No Tie wraps over this area Part No etc Label EXTEN M11

Table 8.124 B1_M11

MOLEX 6WAY SIGNALS JST 6WAY + ADAPTOR WIRE COLOUR

EXTEN M11 PIN 1 EXTEN M11 PIN 2 EXTEN M11 PIN 3 EXTEN M11 PIN 4 EXTEN M11 PIN 5 EXTEN M11 PIN 6

OUT A OUT C +24V +24V OUT B OUT D

M11 PIN 6 M11 PIN 5 M11 PIN 4 M11 PIN 3 M11 PIN 2 M11 PIN 1

TWIST WITH M11 PIN 2 TWIST WITH M11 PIN 1 TWIST WITH M11 PIN 3

8.1.140 INT_STAT (9970-0511)

Label EODD PL4 Label PWR FILT PL8 580 mm

Table 8.125 INT_STAT

PL 4 SIGNALS PL 8 COMMENTS

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14

INTERLOCK _P1 INTERLOCK _P2 INTERLOCK _P3 INTERLOCK _P4 INTERLOCK _P5 INTERLOCK _P6 INTERLOCK _P7 INT_RET_P1 INT_RET_P2 INT_RET_P3 INT_RET_P4 INT_RET_P5 INT_RET_P6 INT_RET_P7

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10 PIN 11 PIN 12 PIN 13 PIN 14

TWIST WITH PIN 8 TWIST WITH PIN 9 TWIST WITH PIN 10 TWIST WITH PIN 11 TWIST WITH PIN 12 TWIST WITH PIN 13 TWIST WITH PIN 14

L UXEL P LATESETTER VOLUME 2 (8-89)

8.1.141 ENG_BLOW_AUTO_WEB (9970-0512)

780mm 50mm 2150mm (sleeved) 150mm

Label FHMB4 PL16

Label BV41
50 mm

Label BV30 Label FHMB4 PL10

125mm

Label BV40

Part number label

50 mm

Label FHMB1 PL10

Table 8.126 ENG_BLOW_AUTO_WEB

AMP CT FHMB4 PL10 SIGNAL NAME MOLEX MINIFIT JR BV30 COLOUR COMMENT

PIN 1 PIN 2 PIN 3

FHMB1 PL10

NOT USED DIVERT VALVE DIVERT VALVE RTN BV30 PIN2 BV30 PIN 3
BV40

RED BLACK

TWIST WITH BV30 PIN 3

PIN 1 PIN 2 PIN 3

FHMB4 PL16

NOT USED LEADING EDGE LEADING EDGE RTN BV40 PIN 2 BV40 PIN 3
BV41

RED BLACK

TWIST WITH BV40 PIN 3

PIN 1 PIN 2 PIN 3

NOT USED AIR KNIFE AIR KNIFE RTN BV41 PIN 2 BV41 PIN 3 RED BLACK TWIST WITH BV41 PIN3

8.1.142 ENG_BLOW_AUTO_PUNCH (9970-0516)

780mm 50mm 2150mm (sleeved) 150mm

Label FHMB4 PL22

Label BV41
50 mm

Label BV30 Label FHMB4 PL10

125mm

Label BV40

Part number label

50 mm

Label FHMB1 PL10

Table 8.127 ENG_BLOW_AUTO_PUNCH

AMP CT SIGNAL NAME MOLEX MINIFIT JR COLOUR COMMENT

FHMB4 PL10 PIN 1 PIN 2 NOT USED DIVERT VALVE

BV30

BV30 PIN2

RED

TWIST WITH BV30 PIN 3

PIN 3

DIVERT VALVE RTN

BV30 PIN 3

BLACK

VOLUME 2 (8-90) S YSTEM C ABLING DESCRIPTIONS

Table 8.127 ENG_BLOW_AUTO_PUNCH

FHMB1 PL10 PIN 1 PIN 2 NOT USED LEADING EDGE BV40 PIN 2 RED TWIST WITH BV40 PIN 3 BV40

PIN 3 FHMB4 PL22 PIN 1 PIN 2

LEADING EDGE RTN

BV40 PIN 3 BV41

BLACK

NOT USED AIR KNIFE BV41 PIN 2 RED TWIST WITH BV41 PIN3

PIN 3

AIR KNIFE RTN

BV41 PIN 3

BLACK

8.1.143 AIRKNIFE_VAC (9970-0517)

Lable BV31 Sol 25mm

100mm Lable FHMB4 PL1

1075 mm

Label I/LOCK BOX VAC PUMP Label FHMB4 PL8 160mm Part number and issue

Table 8.128 AIRKNIFE_VAC

8 WAY MOLEX PL1 SIGNALS I/LOCK BOX VAC PUMP

PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 FHMB4 PL8 PIN 1 PIN 2 PIN 3 BV31 SOL PIN 1 PIN 2

SPARE SPARE PUMP RELAY PUMP RELAY RTN SPARE SPARE SPARE 8 W MOLEX PIN 2 8 W MOLEX PIN 6 BLUE BLACK ( TWIST PAIR PIN 2)

NOT USED COMP RELAY COMP RELAY RTN 8 W MOLEX PIN 4 8 W MOLEX PIN 8 ( 2 WIRES IN PIN 4) (2 WIRES IN PIN 8) RED BLACK ( TWIST PAIR PIN 4)

COMP RELAY COMP RELAY RTN

8 W MOLEX PIN 4 8 W MOLEX PIN 8

RED BLACK ( TWIST PAIR PIN 4)

L UXEL P LATESETTER VOLUME 2 (8-91)

8.1.144 XBLW3_IPWR (9970-0518)

10 mm tinned ends Part No @ Issue DIST L IN 100mm 90mm CHAS
M5

90mm IECIN L IECIN E

DIST N IN 70mm

380mm

50mm

IECIN N

See Note 1

Cable 2 Cable 3

LDIST

120mm brown

FUSE1
FASTON

LDIST
Cable 4
M4

120mm brown 200mm G/Y

M5

FUSE2
M5 RING
(unless otherwise stated)

COMP1E
Cable 5
M4

CHASSIS
M5

10 MM TINNED

COMP2E
Cable 6
M5

250mm G/Y

CHASSIS
M5

LID

500mm G/Y

CHASSIS

Table 8.129 XBLW3_IPWR

CABLE 1 SIGNALS COLOUR

IECIN L FASTON IECIN N FASTON IECIN E FASTON

LIVE NEUTRAL EARTH

DIST L IN DIST N IN CHAS

(TINED END) (TINED END) M5 RING

BROWN BLUE GREEN/YELLOW

VOLUME 2 (8-92) S YSTEM C ABLING DESCRIPTIONS

Volume-Chapt er

SYSTEM CABLING VIEWS

This chapter shows the system functional modules and how they are interlinked by cables described in the previous chapter.

4 4 4 4 4 4 4 4 4 4

System functional view (all variants)........................................................................ 9-2 System DC cabling view (fully-automatic) ............................................................... 9-3 Engine cabling view (System PCB - all variants) .................................................... 9-4 Engine cabling view (Interlock box - all variants) ...................................................9-5 Engine cabling view (FHMB - fully-automatic with punch).....................................9-6 Engine cabling view (FHMB - fully-automatic without punch) ............................... 9-7 Engine cabling view (FHMB - B1/B2 manual/semi-automatic without punch) ..... 9-8 PTM cabling view (fully-automatic with/without punch) ......................................... 9-9 Autofeeder cabling view (fully-automatic with/without punch) ...........................9-10 Interlocks system view (all variants) ...................................................................... 9-11

PLATE HANDLING, VACUUM CONTROL SENSORS

VAC/ DRUM BLOW

ENCODER SENSORS MOTORS

ALERT

MOTORS

SENSORS

MOTORS

SENSORS

MOTORS

TRAVERSE

FHMB(1) (ENGINE)

CAN3 FHMB(2) (PTM) CAN4 FHMB(3) (PTM) FHMB(4) (ENGINE) CAN_UMBIL

CAN5

TRAVERSE (STB) SPINNER/ ENCODER

LCD MIXER FAN ELEVATOR DISTRIBUTION ELEVATOR CONTROL

PTM
AUTOFEEDER

VOLUME 2 (9-2) S YSTEM C ABLING VIEWS

CAN2

MMI

CASSETTE DOOR

SCSI DATA EODD I/F EOD X POD EODD I/L EOD Y HV EODD

DIAGNOSTICS

LPD

BEAMS X&Y

LSB

PROCESSOR

REF CLK VBOMB

LD1 LD3

DISK DRIVE (1)

Figure 9.1 System functional view (all variants)

RFI BOX
OPTICS SENSORS ND FOCUS, APERTURE MOTORS

OPTICS BASE

+24 +15 +15 VBOMB_LPD +24 VBOMB_NDM PL16 PL5 PL15 PL14 PL17 +24 FOCM FOCUS +5 FHMB(4) +24, +36 PWR2 PL31 PL6 STB PL18 PL19 +5 +12, +24 EOD HV EODD +24 FHMB(1) PL18 RIB3/RIB9 +5 SENSOR DIST RIB/RIB2 +24 24V DIST RIB/RIB2 +5 SENSOR DIST PL6 ENG_FHMBPWR +36, +24 CAB_UMBIL TRAVERSE MOTOR PHASE +36 SPINNER MOTOR SPINNER ENCODER TRAVERSE ENCODER I/L BOX VBOMB ND FILTER LPD VBOMB_POD POD VBOMB_APM APERTURE

PL2

+5, +24 VBOMB_PWR

PL4/5 SK2

24V_ENG +24, +36

+36 PSU +5 +24

POWER FILTER EODD

+24 +5

PL3

PSU1

PSU

SYSTEM BOARD BV8_CTRL

PL13 PL31

PL23

MFAN

+24

MIXER FAN

PL11 INT_EMERG FHMB(3) PL18 +5 +24 PL31 PL19 +24 INT_M22 ASSY +24 RIB4/RIB5 +5 SENSOR DIST +24 EMERGENCY STOP

+5 PSU 15 PSU +15 PSU

PL10

+15V

+12, +5

0V

REG

+30 RESISTOR

DISK_PWR

PSU +24

MMI

PWR3_INT

DISK DRIVES

NEW 24V DIST AIR KNIFE RELAY FHMB(2) INT_OUT PL18 +5 RIB8 AIR KNIFE ELEV DIST

Figure 9.2 System DC cabling view (fully-automatic)

+24 PL31 RIB7 +5 PL19 RIB6 +5 ELV_IN CASS ID

RFI BOX FANS

NOTE: SEE CHAPTER 2.9 FOR CABLE PIN DESCRIPTIONS

L UXEL P LATESETTER VOLUME 2 (9-3)

ELEV CONTROL

RFI BOX FHMB_PWR VBOMB_PWR TO FHMB1 (4) OPTICS BASE Tx HV BD Tx PART OF EOD EODY PART OF EOD EODX INT_STAT PSU PWR FILTER BD

24V_ENG TO INTERLOCKS, ENGINE, FEEDER AND CONTACTOR (4)

PSU1

MAINS_PSU

5V 15V -15V 24V(FHMB) 24V(FHMB) 30V 36V EODD 5V, 24V (8V, 900V) EOD

PCB FAN (from 24V rail) LASER BASE X PD DISTRIBUTION PD BD

VOLUME 2 (9-4) S YSTEM C ABLING VIEWS

LASER BASE Y PD DISTRIBUTION CAN2 PSU_CTRL LSB_DATA_VBOMB CAN1 PD BD

EODD_IF

DISK_PWR SYSTEM BOARD

DISK 1

DISK_DATA

IEC INLET

OPTICS ENCLOSURE FAN

V_VBOMB_SENSORS

MAINS_RFI_IN MMI MMI LCD LCD

SCSI

VBOMB_FAN

LPD_HOME VBOMB_LPD VBOMB_LPDM LPD

APERTURE HOME

MAINS_IN MAINS_DIST ENG_INT ALERT PUMP

MAINS_RFI_IN

FILTER (20A)

MAINS_DIST

TO INTERLOCK BOX (4) TO INTERLOCK BOX (4) TO ENG_INT (4) TO CONTROL RELAY (4) TO INTERLOCK BOX (4) VBOMB_POD POD

VBOMB

VBOMB_APM VBOMB_NDM VBOMB_FOCM

APERTURE MOTOR ND MOTOR

Figure 9.3 Engine cabling view (System PCB - all variants)

TEMPERATURE & HUMIDITY SENSOR BD (IF FITTED)

ENG_INT (EXT I/L)

REAR FRAME PANEL WITH CONNECTORS AND CABLE GLAND FOR THE MAINS

ALERT

FOCUS MOTOR V_VBOMB_ENVIRMON

PUMP (ENGINE)

PUMP

FOCUS HOME & FOCUS LIMIT ND HOME

(B2 MAN)

ENG_DIAGS

(B2 MAN)

ENG_PROC

L UXEL P LATESETTER VOLUME 2 (9-5)

(3)

TO PUMP

PUMP

(5, 6, 7)

(3) (3)

PSU_CTRL ENG_INT

OVERRIDE SWITCH
ENG_FHMBPWR

(5, 6, 7) (5, 6, 7)

SERVICE DOOR INTERLOCK I/P COVER INTERLOCK (SEE NOTE 1)

USER DOOR INTERLOCK OUTPUT COVER INTERLOCK

(3)

24V_ENG

8A VAC PUMP CIRCUIT BREAKER PUMP RELAY BV5 I/LOCKCTRL

VAC (5, 6, 7) AIRKNIFE_VAC

(3)

MAINS_RFI_IN

DIST ON/OFF (15A) WITH UNDER VOLTAGE RELEASE I/LOCK_MAINS

I/LOCK_DC (EMG)

CABLE GLANDS

(3)

MAINS_DIST

PWR2 (5, 6, 7)

2A FUSE PSU_I/LOCK 24V PSU I/LOCK_COMP COMP RELAY BV31(1) SCHMERSAL AES 1235 SIEMENS CONTACTOR 3RT1016-1BB42 COIL FUSES I/LOCK_DC

INTERLOCK BOX

COMP_MAINS
NOTE 1: B1 MAN & SEMI-AUTO HAVE I/LOCK LINK NOTE 2: B2 MAN & SEMI-AUTO WITHOUT COMP BOX

FUSES COMP 1 COMP_PANEL COMP 1

COMPRESSOR BOX
(SEE NOTE 2) ENG_FHMBPWR
(5, 6, 7) (5, 6, 7)

(3) (3)

CAN2 ALERT CONTROL RELAY (BV8) SOL_CTRL

(5, 6, 7)

Figure 9.4 Engine cabling view (Interlock box - all variants)

VOLUME 2 (9-6) S YSTEM C ABLING VIEWS

(4) (4) (4)

ENG_FHMBPWR CAN3_ENG CAN5_ENG ENG_M6 ENG_M3/5 PWR2 ENG_M7 ENG_M2 BM6 FRICTION BAND OUTPUT MODULE BM5 REGISTRATION PINS BM3 CENTERING ARMS

PUMP ENG_INT EMERG FRAME WITH PANEL CONNECTORS (TO PTM)

TO (8)

BUFFER INTERLOCK BUFF_M7 BM7 BUFFER FEED TO PROC PCB PCB BS20 BUFFER EXIT

BM2 PUSH BAR CARRIAGE SENS DIST BD ENG_S19/20 SET CAN ID 0 ENG_S10/11

BS19 BUFFER ENTRANCE BUFF_S19/20 BUFFER

FHMB BOARD 4

ENG_FPD_S21

BS21

FPD

(4)
PL18 RIB1/RIB2

ENG_S4 ENG_S5 (OUTPUT)

BS10 REG MOTOR OUT POSITION BS11 REG MOTOR IN POSITION BS4 OUTPUT ENTRANCE BS5 OUTPUT EXIT BS13 CENTERING LH DETECT BS12 CENTERING RH DETECT BS14 CENTERING HOME PCB BS3 PLATE IN PUNCH

PCB PCB

(4)

PL19

BV41 PUNCH_LINK

NEW 24V DIST BD ENG_S6/S112 UMBILICAL

ENG_S14/12/3 ENG_S79 BS79 CHAD TRAY HOME BS112 PUSH BAR FWD LIMIT BS6 PUSH BAR HOME STB

TRAVERSE ENCODER (READ HEAD) TRAVERSE MOTOR SPINNER MOTOR

ENG_BLOW

BV30 BV41 (2)

SPINNER ENCODER

VAC/AIRKNIFE_VAC ENG_BLOW_AUTO_PUNCH

CONTROL RELAY (BV3)

MIXER FAN (BV3) MFAN BS80 MIXER FAN DETECT

CAN3_ENG (4) (4) (4)

ENG_FHMBPWR

FHMB BOARD 1 PL18 RIB3

SENS DIST BD (INPUT)

ENG S1/2 SET CAN ID 0 ENG S8/9

PCB PCB

BS1 INPUT ENTRANCE BS2 INPUT EXIT

CAN2
SOL_CTRL

BS8 PUNCH MOTOR ON POSITION BS9 PUNCH MOTOR OFF POSITION ENG_EARTH

ENG M1 ENG M4

BM1 FRICTION BAND INPUT MODULE BM4 PUNCH

Figure 9.5 Engine cabling view (FHMB - fully-automatic with punch)

L UXEL P LATESETTER VOLUME 2 (9-7)

(4) (4) (4)

ENG_FHMBPWR CAN3_ENG CAN5_ENG ENG_M6 ENG_M36/37 PWR2 ENG_M7 ENG_M2 ENG_S21 BM6 FRICTION BAND OUTPUT MOD

PUMP ENG_INT EMERG FRAME WITH PANEL CONNECTORS (TO PTM)

TO (10.8)

BM36 REGISTRATION PINS BM37 SWING ROLLER

BUFF_LOCK BUFF_M7

BUFFER INTERLOCK

BM2 PUSH BAR CARRIAGE BS21 FPD BS109 SWING ROLLER HOME

BM7 BUFFER FEED TO PROC

BUFFER TO PLATE PROCESSOR

FHMB BOARD 4

ENG_S109/110

BS110 SWING ROLLER IN DRUM BS19 BUFFER IN PCB PCB BS20 BUFFER OUT

(4)

REG_FHMB REG_PIN

REG PIN BD

SENS DIST BD

ENG_S19/20

BUFF_S19/20 BUFFER

BS104 REG PIN CONTINUITY

ENG_S4 ENG_S5

PCB PCB

BS4 OUTPUT ENTRANCE BS5 OUTPUT EXIT

(4)

PL18 PL19

RIB1/RIB2

(OUTPUT)

BV41 WEB_LINK BS100 REG PIN MTR HOME

NEW 24V DIST BD ENG_S6/S15 UMBILICAL

ENG_S100/103

BS103 REG PIN MTR IN TRAVERSE ENCODER (READ HEAD) TRAVERSE MOTOR STB SPINNER MOTOR SPINNER ENCODER EDGE DETECT EDGE DETECT BD

BS15 PUSH BAR FWD LIMIT BS6 PUSH BAR HOME

ENG_BLOW_AUTO_WEB

BV30 BV40 BV31 (2)

VAC/AIRKNIFE_VAC ENG_BLOW

CONTROL RELAY (BV3)

LASER

MIXER FAN (BV3) MFAN BS80 MIXER FAN DETECT

CAN3_ENG (4) (4) (4)

ENG_FHMBPWR

FHMB BOARD 1 PL18 RIB3

SENS DIST BD (INPUT)

ENG S1/2

PCB PCB

BS1 INPUT ENTRANCE BS2 INPUT EXIT

CAN2
SOL_CTRL

ENG M1

BM1 FRICTION BAND INPUT MODULE

ENG_EARTH

Figure 9.6 Engine cabling view (FHMB - fully-automatic without punch)

VOLUME 2 (9-8) S YSTEM C ABLING VIEWS

(4) MAN_STOP
ENG_CAN_FHMB1_4

ENG_INT

ILOCK_LINK

BUFF_LINK (MANUAL ONLY)

BUFFER TO PLATE PROCESSOR

ENG_M36/37 (B2) PWR2 SEMI_M36/37 (B1) ENG_M7 ENG_M2 ENG_S21 FHMB BOARD 4 BM2 PUSH BAR CARRIAGE BS21 FPD BS109 SWING ROLLER HOME ENG_S109/110 BS110 SWING ROLLER IN DRUM BS19 BUFFER IN PCB PCB BM36 REGISTRATION PINS BM37 SWING ROLLER BUFF_M7 BUFF_LOCK BUFFER INTERLOCK NOTE 1 BM7 BUFFER FEED TO PROC

(4)

(4)

REG_FHMB

REG PIN BD

REG_PIN BS104 REG PIN CONTINUITY

SENS DIST BD

ENG_S19/20

BUFF_S19/20 BUFFER

NOTE 2

BS20 BUFFER OUT

ENG_S4 ENG_S5 PL18 PL19 RIB1/RIB2 (OUTPUT)

PCB PCB

BS4 OUTPUT ENTRANCE BS5 OUTPUT EXIT

(4)

BV41 WEB_LINK BS100 REG PIN MTR HOME

NEW 24V DIST BD ENG_S6/S112 UMBILICAL

ENG_S100/103

BS103 REG PIN MTR IN TRAVERSE ENCODER (READ HEAD) TRAVERSE MOTOR STB SPINNER MOTOR

BS112 PUSH BAR FWD LIMIT BS6 PUSH BAR HOME

ENG_BLOW_AUTO_WEB

BV30 BV41
EDGE_DETECT MIXER FAN (BV3) MFAN BS80 MIXER FAN DETECT EDGE DETECT BD

SPINNER ENCODER

AIRKNIFE_VAC

CONTROL RELAY (BV3)

SOL_CTRL

EDGE_LASER

LASER

ENG_M38 PL18 RIB3 (B2) FHMB4 (PL23)

BM38 OUTPUT MOTOR SENS DIST BD (INPUT) B2_FRONTSENSOR ENG_S1/2 (ENG B1) CAN ID0 PCB PCB BS1 INPUT ENTRANCE BS2 INPUT EXIT BS114 CENTERING CON 1 BS113 CENTERING HOME

(4) (4)

ENG_FHMB_PWR

FHMB BOARD 1

CAN2

(4)

SOL_CTRL

BS116 PLATE PUSHER HOME FRONT_SENSOR_EXT ENG B1_S114 PCB BS118 PLATE ON PLATEN ENGB1_M10 BM10 PLATE CENTERING EXT_M11 B2_M11 ENG_EARTH BM11 PLATE PUSHER ENG_M1 BM1 FRICTION BAND INPUT MODULE NOTE 1: B1 SEMI-AUTOMATIC HAS BUFFER INTERLOCK NOTE 2: B1 AND B2 MANUAL DO NOT HAVE A BUFFER

Figure 9.7 Engine cabling view (FHMB - B1/B2 manual/semi-automatic without punch)

24V
36V INT_M21/25 BM25 RETARD DROP BS61 STACK HEIGHT TOP BS44 STACK HEIGHT HOME PCB INT_S49/50 PCB INT_S66/53 PCB PCB BS43 CASS EMPTY BS48 NUDGER DETECT SENSOR DIST BOARD INT_S52 PCB INT_S56/57/65 BS65 CASS AT NUDGER BS56 RETARD UP BS57 RETARD DOWN BM21 STACK HEIGHT

CAN5_INT INT_S44/61 PL18 PL19 RIB4/RIB5

LIMIT PLUG PL9

EMERGENCY STOP SWITCHES

BS52 PARK POSITION (PRE-INPUT) BS47 STACK HEIGHT POSITION

BS49 RETARD MADE

BS50 PLATE AT PRE DIVERTER BS53 PAPER TENSIONER BS66 INTERLEAF NIP CLEAR

FHMB BOARD 3

INT_M22ASSY

BM22 NUDGER & TAKEAWAY BM23 NUDGER LIFT BV20 DIVERTER BM24 INTERLEAVE DRIVE
INT_S45ASSY

BS51 PAPER POST DIVERTER BS45 NUDGER DOWN LIMIT

BS46 NUDGER UP LIMIT

CAN4

24V INT_M20/27 INT_S55/59 BM20 CASSETTE FWD SET CAN ID 1

36V

ENGINE

NEW 24V DIST BOARD

TO EMERG INT_S62/71 PL19 BV22 CASS DOOR LOCK BS72 CASSETTE DOOR CLOSED BV25 DOCKING LIGHT BM28 Z DIRECTION CONTROL BS36 BS37 BS38 BS39 BS40 CASS ID BOARD

INT_EMERG

BS55 PAPER POST DIVERTER PCB BS59 PLATE PAST DIVERTER

TO CAN5_ENG

BM27 X DIRECTION DOOR BM62 X DIRECTION DOOR UP BS71 X DIRECTION DOOR DOWN RIB6

TO ENG_FHMBPWR

PWR3_INT

INT_S41/42 INT_S76 PCB

BS41 CASS FWD LIMIT BS42 CASS REV LIMIT BS76 FRONT DOOR OPEN

TO CAN3_ENG

CAN3_INT

FHMB BOARD 2

CASS ID1 CASS ID2 CASS ID3 CASS ID4 CASS ID5

FROM (5, 6, 7) BM26 ELEVATOR STOP BM26 ELEVATOR STOP BS74 VECTOR DRIVE ALARM BS75 VECTOR DRIVE OVERLOAD PL18

TO ENG_INT

FEED_INT

INT_OUT RIB7

TO ELEVATOR DIST BD TO ELEVATOR CTRL BD

FRAME WITH PANEL CONNECTORS (ENGINE) (EARLY MACHINES ONLY) PTM AIR KNIFE

INT_OUT

PTM I/LOCK

TO (9)
BV23 AIR KNIFE AIR KNIFE FAN INT_EARTH NOTE 1: KNIFE MOVED TO ENGINE ON LATER MACHINES FRAME WITH PANEL CONNECTORS

24V

Figure 9.8 PTM cabling view (fully-automatic with/without punch)

INT_MAINS

L UXEL P LATESETTER VOLUME 2 (9-9)

TO PUMP_PTM

INT_MAINS

MAINS TO ELEVATOR SECTION

RIB8

BS30 ELEVATOR (TOP) BS31 ELEVATOR (BOTTOM) BS32 ELEVATOR SHELF 1 BS33 ELEVATOR SHELF 2 BS34 ELEVATOR SHELF 3 ELEVATOR DISTRIBUTION BD

BS78 DOCKING RH BS77 DOCKING LH DOCKING INDICATOR

VOLUME 2 (9-10) S YSTEM C ABLING VIEWS

BS63 Z DIRECTION UP BS70 Z DIRECTION DOWN BM28 Z DIRECTION CONTROL

PTM

CASSETTE DOOR LOCK ELV_LOCK ELV_LOCKS SCHMERSAL SOLENOID LOCK (BV22) CONTACTS (BS72) BM26 ELV_IN ELEVATOR CONTROL BD RED ORANGE ELV_CTRL ELV_CON_24V RED PART OF FILTER BOTTOM LIMIT TOP LIMIT

FROM (10.8)

FRAME WITH PANEL CONNECTORS (PTM)

MAINS_ELV_IN HITACHI RFI FILTER

INVERTER inc BS74 and BS75

INV_MOTOR CABLE 2

SIEMENS CONTACTOR 3RT10161BB42 Contacts for BS73

Figure 9.9 Autofeeder cabling view (fully-automatic with/without punch)

INV_MOTOR CABLE 1 ELEVATOR MOTOR

ELEV_EARTH

AES 1235
CABLE 'ENG_INT'

S22 PTM TOP H (6) PIN 9 6 7 8 PIN 2 PIN 7 PIN 4 1 3 2 3 4 8 4 4 4 4 8 8 4 8 8 7 3 3 3 3 7 7 3 7 7 6 2 2 2 2 6 6 2 6 6 ENG I/P F (5) ENG SERV G (4) ENG USER I (3) ENG O/P A (2) BUFFER J (1)

I/LOCK PIN3

S14

I/LOCK PIN7

EXTERNAL DLA CONNECTIONS B 2 4

OVERRIDE KEY SWITCH OFF C

S13

F1B 1A F1A

I/LOCK PIN2

S21

F2B 1A F2A

I/LOCK PIN5

CABLE 'ENG_INT' + 15V FROM PSU -

1-6 SWITCH POSITION WITH PANELS CLOSED AND NOT OVERRIDDEN LSB SEE NOTE ON ROUTE RELAY ON LSB +15V TO VBOMB STAT 1 STAT 2 STAT 3 (PL4) STAT 4 STAT 5 STAT 6 EODD S/W STATUS (PSU - CTR) NOTE: 'ENG_INT' TO PWR FILTER TO 'INT_STAT' TO EODD

13

PIN2

14

X1 SSB
ILOCK SENSORS

CONFIRMS CONTACTOR SWITCHING 52 SSB 51

FROM INTERLOCK BOX +24V FROM FHMB POWER +24V 1L1 3L2 5L3 +24V 21NC +24V +24V GND A1+ I/LOCK CONTACTOR (I/L BOX) A222NC 6T3 4T2 2T1 +36V

SENSORS AVAILABLE IN DIAGNOSTICS

A2-

+24V GND

A1+

+24V

TO FHMBs +24V POWER TO FHMBs +36V POWER

ILOCK OVERRIDE KEY ILOCK CONTACTOR (ENGINE) ILOCK CONTACTOR (AUTOFEEDER) CASSETTE DOOR LOCK

S23

F3B 1A F3A

+24V

S24

READ_PSU_STATUS OK MEANS COVER IN POSITION ILOCK_RELAY GIVES INCORRECT READING READ_SENSOR ILOCK_OVERRIDE OFF MEANS INTERLOCKS NOT OVERRIDDEN READ_SENSOR ILOCK_RELAY OFF MEANS INTERLOCKS OK, OK TO FEED POWER TO FHMB'S & LASER READ_SENSOR BS73 OFF MEANS INTERLOCKS OK, OK TO FEED AC TO ELEVATOR MOTOR READ_SENSOR BS72 ON MEANS DOOR CLOSED, OK TO FEED AC TO ELEVATOR MOTOR

FUSED +24V

I/LOCK PIN4

AUTOFEEDER
INVERTER E L N BS72RTN 12 22 A2 FUSED +24V BV22RTN ABS LIMIT TOP ABS LIMIT BOTTOM FILTER L1 V/T2 U/T1 N/L3 W/T3 FHMB(2) BS73RTN

CONTACTOR (ELEVATOR) 4T2 2T1 6T3 22NC A1+ 3L2 1L1 5L3 21NC A2BS73 +24V GND MAINS INPUT FROM PTM

ELEVATOR MOTOR V U W FHMB(2) BM26

Figure 9.10 Interlocks system view (all variants)

SOL LOCK BS72 FUSED +24V BV22 A1 21 11 DOOR DRIVE FHMB(2) +24V

L UXEL P LATESETTER VOLUME 2 (9-11)

INTERLOCK BOX

VOLUME 2 (9-12) S YSTEM C ABLING VIEWS

Volume-Chapt er

ROUTINE MAINTENANCE
This chapter describes the required service tools, the service schedule and the main service procedures for a site visit.

1.1 Field Service Tools

Useful tools for a service visit include: Metric Allen key set (1.5 mm to 10 mm). Keys required are 3, 4, 5, 6 and 8 mm; sizes 1.5, 2, 2.5 and 10 mm will also be useful as spares. Metric socket set and open-ended spanner set, including 24 mm socket plus 27 mm and 28 mm open-ended spanner. Digital voltmeter (DVM). Laptop PC - minimum specification: Pentium 32 Mbyte RAM, 800x600 (Min) screen resolution with Windows NT4, Lotus Notes (V4.6) and modem. This tool is optional. Pliers (medium and small). Side-cutters. Soldering iron (transportable, gas type) and solder. Flat-blade screwdriver (medium and small). Philips screwdriver (medium and small) - magnetic. Dummy pozidrive screwdriver. Steel ruler (6 in/150 mm).

4 4 4 4 4 4 4 4

Field Service Tools ..................................................................................................... 1-1 Overriding the Interlocks ...........................................................................................1-2 Opening Service Covers ............................................................................................ 1-3 Maintenance Schedule ...............................................................................................1-4 Cleaning Procedures.................................................................................................. 1-5 Maintenance Procedures ...........................................................................................1-9 Checking the Traverse .............................................................................................1-14 Checking the Platesetter Output............................................................................. 1-16

VOLUME 3 (1-2) R OUTINE MAINTENANCE

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.

1.2 Overriding the Interlocks

See Figure 1.1. Cover interlocks are temporarily overridden by a two-position keyswitch fitted on all engine variants. Remove the service side engine cover to access the switch (fully-automatic) or open the service side cover (manual and semi-automatic).
KEYSWITCH (IN OVERRIDE POSITION)

KEYSWITCH IN INTERLOCKS ENABLED POSITION

ENGINE - SERVICE SIDE (COVER REMOVED FOR CLARITY)

Figure 1.1 Interlock override - keyswitch location (fully-automatic)

L UXEL P LATESETTER VOLUME 3 (1-3)

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 Opening Service Covers

1.3.1 Manual and Semi-Automatic
The service side door on Manual and Semi-Automatic machines are locked by screw fixings shown in Figure 1.2. Note that earlier machines may have doors without the screw fixings. Access to the optics base and RFI box is the same as the Fully-Automatic machine.

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)

AUTOFEEDER

PTM

ENGINE

OPTICS BASE

LOWER COVER USER SIDE NOTE: CASSETTE DOOR LOCK IS S/W CONTROLLED BOTTOM SCREW LOCK TOP SCREW LOCK NOT LOCKED

Figure 1.2 Removing locked covers (fully-automatic)

VOLUME 3 (1-4) R OUTINE MAINTENANCE

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.

1.4 Maintenance Schedule

Recommended servicing visits for the platesetter are every six months where the engineer needs to perform checks and procedures based on the schedule below. Before a service visit, make sure the operator has completed all the routine maintenance tasks described in the Operator's Manual. Routine service procedures are constantly added and revised to ensure product reliability over the long term. Make sure that you have consulted the latest releases of the Technical Information Sheets (TIS) provided by FFEI (UK).
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.

Complete the following scheduled tasks:

Six-Month Visit:
1. Discuss any problems the customer has had with the machine since the last
service visit.

2. Check that all operator maintenance tasks have been completed. 3. Output a full-size image to check for correct machine operation. 4. Output and check four full-size images for any indications of quality faults. 5. Check error statistics and the error log (elog) file: see Volume 2 Section 1.5.3. 6. Complete the required cleaning procedures: see Section 1.5. 7. Check and adjust the punch if 35,000 punch operations have occurred since the
last maintenance visit: see Section 1.6.2.

8. Check for push bar pitch ring flake containment: see Section 1.6.3. 9. Check that the drum blow system is operational: see Section 1.6.4. 10. Check the extinction levels of the lasers: see Section 1.6.5. 11. Check the absolute limit switches on the elevator: see Section 1.6.7. 12. Check the trolley and cassette for damage: see Section 1.6.7.1.

L UXEL P LATESETTER VOLUME 3 (1-5)

13. Check the paper detect sensors: see Section 1.6.8. 14. Check and re-align the traverse ball cage and carriage: see Section 1.7.1. 15. Check plate output: see Section 1.8. 16. Run the levelling utility to check for ball cage creep: see Section 1.7.1. 17. Check the optics system for Focus: see Volume 3 Section 4.4. 18. Check the optics system for image form on the plate: see Section 4.7. 19. Carry out the vacuum maintenance procedures listed in the OEM manual. 20. Check the PAT unit for correct operation, change of filters and note if the door
gasket is intact.

21. Complete the pre-cautionary diagnostics tasks: see Section 1.6.6. 22. Output and check a full-size image for correct machine operation before
returning it to the customer.

Twelve-Month Visit:
1. Replace the push bar spring shoes, see Volume 3 Section 2.4.5.

1.5 Cleaning Procedures

Customers need to be aware of the importance of a clean environment in and around the platesetter.

1.5.1 Cleaning the Spinner Mirror and L6 Lens

CAUTION: Avoid touching or marking the lens (L6) in front of the spinner mirror.

Only use tissues/wipes soaked with IPA.

1. Access the spinner mirror.

CAUTION: Only use light pressure when applying a wet wipe. Never rub a coated mirror surface with a dry wipe. Only use wet tissues or wipes.

2. Soak a lens tissue with IPA. 3. Draw the lens tissue across the spinner mirror without applying direct pressure. 4. Repeat step 2. and 3. until the mirror is clean.
The tissue must be kept damp and changed frequently throughout this procedure. Check for solvent streaking when the cleaning is complete.

1.5.1.1 Focusing Lens (L6)

The lens is held by an assembly of two metal plates, adjusted by screw fixings and two springs. These are accurately set at the factory and are not field adjustable.

1. Use a cotton bud, wrapped with a lens tissue soaked in IPA, and gently clean

the lens on both sides, see Figure 1.3. Check that there are no fibres remaining on the lens.

VOLUME 3 (1-6) R OUTINE MAINTENANCE

2. Carry out the setups in Table 4.1 on page 3-4-3.

TRAVERSE CARRIAGE

L6 LENS

BAFFLE ASSEMBLY

CLEAN REAR CLEAN FRONT

Figure 1.3 Cleaning focusing lens (L6)

1.5.2 Cleaning the Traverse Assemblies

Cleaning the linear scale, rail and readhead is only carried out as necessary to maintain reliable operation. Cleaning periods vary depending on the amount of contamination collecting on the scale or readhead. Make sure all the unused beam holes are blanked out with black felt or self-adhesive tape.

1.5.2.1 Linear Scale and Drive Rail

A lacquer coating is applied to protect the scale and render it easy to clean. Use the following procedure:

1. Clean the rail and scale with a clean dry cloth after removing any abrasive
particles.

2. Gently wipe along the scale with a lint-free cloth to remove dust.

L UXEL P LATESETTER VOLUME 3 (1-7)

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 NHeptane.

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.

1.5.2.3 Drive Rail Wiper

This procedure is completed when the traverse carriage has been moved to extenders and detached from the rail.

1. Remove the drive rail wiper, see Volume 3 Section 3.3.4. 2. Clean the wiper by brushing any dust particles from the felt pad. If the pad is
too dirty or damaged, then remove and replace the wiper assembly.

3. Refit or replace the wiper.

1.5.3 Cleaning the PTM Assemblies

NOTE: TAK cloths used for the removal of very fine particles can be ordered from FFEI.

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.

Guides and Surfaces

Plate and paper dust must be removed from the guides to prevent plate scratching.

Air Knife
This module does not require maintenance but check for any accumulated contaminants inside the system.

VOLUME 3 (1-8) R OUTINE MAINTENANCE

1.5.4 Cleaning the Engine Assemblies

Drum
1. Use a small hand-held vacuum cleaner to remove dust from the inside of the
drum and around the traverse rail and beam.

2. Vacuum clean the left and right-hand side contamination traps near the push 3. Polish the drum with TAK cloths, making sure the vacuum holes are clear of
any dust and debris.

bar tracks. Generally, dust is pushed to the side of the drum as plates are loaded.

Input and Output Modules

Clean the rubber rollers and belts with a damp lint-free cloth soaked in warm water.

Punch
Clean the punch surfaces with a soft brush and a TAK cloth.

Push Bar (Cleaning)

1. Yearly: remove the push bar and replace the two push bar shoes. 2. Clean and replace the push bar then record the change in the machine Log Book. 3. Check for mechanical/vacuum conformance and for plate skew.

LPD
1. The LPD lens and the box assembly interior surfaces are cleaned with Ethylalcohol.

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 cotton 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 material.

FPD Filter Lens

1. From its hole inside the drum, clean the FPD filter lens with an air duster (if
available).

2. Carry out the setups in Table 4.1 on page 3-4-3.

PAT Air Filter

1. Follow the filter maintenance procedures in the supplied in the PAT Installation
and Operation Guide.

2. Check the door gasket. 3. Clean the air inlet grille at the base of the unit.

L UXEL P LATESETTER VOLUME 3 (1-9)

1.5.5 Cleaning the Module Interior

Use a small hand-held vacuum cleaner (with a soft nozzle) to remove dust from the following areas: base plate floors doors, lids and covers all recesses inside the machine clean the inlet filter on the drum vacuum pump. Check that the contamination control system is operating properly where: contaminants are picked up from the nudger/takeaway rollers contaminants are brushed from the plate, belts and rollers, and collected by vacuum bars.

1.5.6 Cleaning the Cassette

The cassette should be cleaned and inspected at each plate load using a TAK cloth or a damp cloth rinsed in warm water. Clean the following: Platen side guides. Cassette lids. Cassette ball transfers.

1.5.7 Cleaning the Elevator

Inspect and clean the elevator shelves and motor control compartment. Chain links are internally self-lubricating and only need to be visually checked for signs of corrosion on the side plates if the machine is operating in a humid environment. Where there are signs of external corrosion, the 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.

1.6 Maintenance Procedures

1.6.1 Interlock Checks
1. Open and close a cover and then check the MMI for the appropriate Error
Handling screen. Check that all the plate handling motors, the laser module and spinner motor are switched off.

2. Check that elevator motor switches off when the cassette door is opened. 3. Repeat the same procedure for each cover in turn.

1.6.2 Punch Checks

1. Check and adjust the punch if 35,000 punch operations have occurred since the
last service visit.
diagnostics/log_utils> disp_stats

4 4

VOLUME 3 (1-10) R OUTINE MAINTENANCE

2. Use the information in Volume 2 Section 3.4.2.6 to service the punch. 3. Record punch numbers and all service procedures in the machine Log Book.

1.6.3 Push Bar Flake Containment Checks

NOTE: This procedure should be completed at every scheduled and unscheduled visit to a customers site.

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.

1.6.4 Drum Blow Checks

1. Turn on drum blow as follows:
set bv31 on set bv30 off set bv41 off

2. Check for air flow through the blow and main areas of the drum. If an air knife
is fitted:
set bv41 on

3. Check for air flow through the air knife and turn off drum blow:
set bv31 off set bv41 off

1.6.5 Laser Extinction Level Checks

The aim of this check is to set the required extinction ratio between the laser drive power and the laser bias power for a required laser.

1. Measure laser extinction values for both lasers as follows:

diagnostics/service/optics/laser>measure_extinction_ratio Laser X extinction ratio = 205.442322 Laser Y extinction ratio = 193.664627

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)

to increase the extinction ratio of a laser you need to decrease the bias current to decrease the exctinction ratio of a laser you need to increase the bias current.

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 bias dac value (dec) Working Laser Y bias dac value (dec) 563 526 hex 233 20e

Working Laser X/Y bias DAC values are changed using the backspace and numerical keys: to increase the extinction ratio of a laser you need to decrease the bias current to decrease the exctinction 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.

1.6.6 Pre-Cautionary Checks

1. Check if ND filter adjustment is running out during calibration. 2. Check the laser end of life statistics using diagnostic commands:
>laser_x_stat >laser_y_stat

A 40% change in laser current since installation indicates the laser has aged significantly. It does not indicate the end of life; in fact, the laser could last for several more months. You should advise the service manager and prepare for the possibility of a laser failure.

3. Update NVRAM parameters to HDD and keep a copy on the system:

4 4 4 4

Remember Incorrect Values can cause damage dec Working Laser X bias dac value (dec) 563 Working Laser Y bias dac value (dec) 526 Confirm Change Updating Values UPDATE

VOLUME 3 (1-12) R OUTINE MAINTENANCE

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.

1.6.7 Absolute Limit Sensor Check

1. Visually check that the two absolute limit sensors on the Autofeeder are reset
(button pulled out). bottom shelf):

2. Enter the following command to move the elevator (where a = top shelf and e =
main> diagnostics/service/medtran> move elevator <e>
WARNING: Understand the dangers of moving parts on the Autofeeder.

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.

1.6.7.1 Trolley and Cassette Checks Trolley

As a maintenance procedure, check the following: corner buffer blocks are not damaged the magnetic docking sensor operates correctly the retainer spring and castor brakes operate correctly.

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)

5. Make sure that the interior is dust-free.

Refer to FFEI Customer Services (UK) for information on how to replace cassette fittings, such as the latch, buffer corner, clamp and magnetic catch. If an error is reported that points to failed ID readings, first check that the cassette ID label is in place and is correctly aligned with the sensors.

1.6.8 Paper Detect Sensor Check

This procedure is used to check if the PTM paper detect sensors (BS51 and BS55) are operational:

1. Reboot the platesetter and, during the boot sequence, press ctrl-c at the second
request to stop the machine.

2. Open Main diagnostics and run the sensor check utility:

main>diagnostics/service/sensors/read_con ip

3. Using an interleaf sheet, check that the two sensors switch for all possible
positions between the sensors. Move the sheet up, down and across to check that both sensors switch for the full range of paper positions.

4. Refer to Volume 3 Section 2.3.2.1 for more information if either sensor needs to
be set up.

1.6.9 Light-Tight Checks

These checks only need to be completed if the customer complains of plate fogging.

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 command, fog_time, will allow you to change the fog warning settings.

VOLUME 3 (1-14) R OUTINE MAINTENANCE

1.7 Checking the Traverse

1.7.1 Aligning the Carriage and Ball Cage
Both the traverse carriage and ball cage are setup manually so that they always move back and forward as aligned assemblies. The procedure below can be done at either end of the Engine.

1. Hold the ball cage and push the carriage back until a length of the cage is
exposed.

2. Pull the carriage forward, without holding the ball cage until the two assemblies
are inline with the screw fixing as shown in Figure 1.4. carriage accurately.

3. You may have to repeat steps 1. and 2. several times to align the ball cage and 4. Complete the engine traverse level check below.

CARRIAGE RAIL

BALL CAGE

SERVICE END VIEW

ALIGN BALL CAGE AND CARRIAGE RAIL HERE

Figure 1.4 Carriage rail and ball cage alignment

1.7.2 Engine Traverse Level Check

Use this procedure to run a service utility that checks if the engine is level from the traverse end-to-end. The aim is to minimise the amount of ball cage creep as the carriage continually moves backwards and forwards along the rail. If there is a risk of the Engine settling into a soft floor surface, then repeat the check after 24 hours.

1. Make sure the ball cage and traverse carriage are correctly aligned using the
method in Section 1.7.1.

L UXEL P LATESETTER VOLUME 3 (1-15)

2. Check that the spinner and traverse are disabled. (They are enabled if the
diagnostics/service/spinner> stop diagnostics/service/traverse> halt

application has been running). Select the following from Main Diagnostics:

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.

MEASURE AND CORRECT FOR CAGE CREEP

RUN TRAV. TEST CARRIAGE RAIL

ALIGN AND MEASURE

BALL CAGE

V-GROOVE

Figure 1.5 Check traverse level

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

Creep Towards Service End (Adjust Up)

1 mm 2 mm 3 mm
1

Creep Towards User End (Adjust Down)

1 mm 2 mm 3 mm
1

/2 TURN

/2 TURN

1 TURN 11/2 TURN

1 TURN 11/2 TURN

9. Repeat steps 2. to 8. until creep is within the specification. 10. Adjust the PTM and Autofeeder to match any Engine adjustment. Tighten the
PTM-Engine fixing bolts (4-off, M5) and the PTM-Autofeeder bolts (4-off, M5).

1.8 Checking the Platesetter Output

1.8.1 All Platesetter Variants
1.8.1.1 Check Image Form Adjustment
A full description of the image form check and correction on for a B1 plate only is given in Volume 3 Section 4.7.

1.8.1.2 Check Expose Tint Quality

1. Expose PI `tint' (1028 mm x 770 mm) 50% tint from the Run Test menu on the
MMI and process the plate.

2. Using a densitometer, check at the nine plate points shown in Figure 1.6:
Background points (reference) are at 0 %. Saturated points (reference) are at 100 %. Tint points conforms to 50 %. ( 1 %.) prediction errors.

BACKGROUND (0%)

SATURATED (100%) IMAGE

TINT (50%)

Figure 1.6 Tint predict check

3. Failure to predict 50% (+1%) could be caused by:

dirty spinner and/or optics

L UXEL P LATESETTER VOLUME 3 (1-17)

incorrect focus adjustment poor mechanical/vacuum conformance poor Processor conditions for: pre-heat process time developer scrub pressure developer pH reading should be 12.0 0.2.

Consult FFEI (UK) Customer Support to resolve a 50% predictive fault.

1.8.1.3 Check Image Quality

1. Expose the S&T pages (PI images) at a fixed PI resolution of 96 and test the
image quality against the supplied reference plates for: screen quality raster quality vignette quality dot prediction accuracy 1% (max). highlight dot quality. Use S&T image plates shipped with the machine as the test reference plates.

2. If the issue cannot be resolved then contact the FFEI Support Centre (UK).

1.8.2 Platesetters Fitted With a Punch

After checking a customer output image you may need to complete some of the following procedures to ensure image/plate quality and accuracy: Image form adjustment: see Section 1.8.1.1. Tint quality: see Section 1.8.1.2. Plate Load in Drum: see Section 1.8.2.1 Image position and skew: see Section 1.8.2.2. Punch crop accuracy: see Section 1.8.2.3 Punch centering: see Section 1.8.2.4. Image traverse centre position: see Section 1.8.2.5. Image base offset: see Section 1.8.2.6. Image quality: see Section 1.8.1.3.

1.8.2.1 Check Plate Load in Drum

Use this procedure on a fully-automatic machine if there is inaccurate plate centering and poor plate transit from the PTM to the drum. When loading large plates it is important that the plate is advanced to the centre of the drum on machines where the punch mouth is 1175 mm wide. If the plate

4 4 4 4

VOLUME 3 (1-18) R OUTINE MAINTENANCE

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)

Figure 1.7 Aligning the PTM, Engine and plate

6. If there is a misalignment then check the following:

The PTM to Engine connecting bolts are tight and the two units are parallel. The plates are centred in the cassette and the plate guides are correctly adjusted. Check that the Engine interface guide plate and the transport rollers are parallel. If they are not, then adjust the PTM position by loosening the 4-off M5

L UXEL P LATESETTER VOLUME 3 (1-19)

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.

1.8.2.2 Check Image Position and Skew

See Figure 1.8. This procedure does not apply to variants without a punch.

1. Full Punch: Expose four identical plates and determine the range of skew
between A and B using a glass ruler and magnifier. Measure between the leading plate edge and the start of the image area.

2. Add the four values for A skew and divide by four to obtain the average value. 3. Repeat the same calculation for B skew. 4. Subtract A average value from B average value.
The difference should be less than 50 microns.

5. Dummy Punch: Check the squareness and position of the image in relation to the
leading edge of the plate where A - B is less than or equal to 200 microns.
A B

IMAGE
PLATE

Figure 1.8 Dummy punch position and image skew check

1.8.2.3 Check for Punch Crop Accuracy

See Figure 1.9. This procedure only applies to variants with a punch fitted. Use a glass or steel ruler and a x10 eyeglass to check the punch crop depth from the bottom of the depth to the top of the plate where A - B is less than 200 microns.

VOLUME 3 (1-20) R OUTINE MAINTENANCE

PLATE

Figure 1.9 Full punch crop accuracy

1.8.2.4 Check Punch Centering

See Figure 1.10.

1. Full Punch Only: check that the crop positions are centered on the plate.
The centering mechanism is adjustable.

2. Check that the punch protocol matches the examples shown in Volume 2
Figure 3.63.

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)

the half width is 6 mm, or 5 mm for a round crop.

4. Centre accuracy should be 1 mm, so A dimension for the centre is 119 mm and
B is 120 mm.

5. Check that the punch crops are the correct depth (standard depth = 12 mm but
custom punches can be 11 mm).

6. Check that the holes are cleanly cut, without debris in the hole corners or burrs.

1.8.2.5 Set Image Traverse Centre Position

A horizontal offset check is required to accurately position an image on the plate. You can adjust the horizontal positions by entering new base offset values in NVRAM.
NOTE: This procedure is not required on machines with Edge Detect.

See Figure 1.11.

1. From Main Diagnostics obtain the NVRAM menu:

diagnostics/log_utils/disp_nvram

2. Expose a PI `tint' on a 1028 mm x 770 mm plate. 3. Check that the image is centred on the plate with equal distances from the left
and right plate edges.

0 m LEFT

PLATE CENTRE

1220000 RIGHT (PERISCO END)

IMAGE PLATE TRAV_CENTRE_POSITION = -610000 m

Figure 1.11 Centering the image (dummy punch)

4. Adjust the TRAV_CENTRE_POSITION parameter to move the image towards the

centre using the diagnostics:
rd_centre_posn wr_centre_posn

For instance, to move the image 10 mm (10,000 m) to the right of the plate, use the example formula:
-6100000 + (- 10000) = -620000

VOLUME 3 (1-22) R OUTINE MAINTENANCE

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

IMAGE

PLATE

Figure 1.12 Centering the image (full punch)

1.8.2.6 Set Image Base Offset

A vertical offset check is required to accurately position an image on the plate. You can adjust the vertical positions by entering new base offset values in NVRAM. See Figure 1.13. This procedure adjusts the non-imaged area at the top of the plate (punch end). It is normally set at a default of 25 mm (25,000 m).

1. Expose a PI `tint' on a 1028 mm x 770mm plate. 2. Check for the default area, see Figure 1.13. 3. Modify the IMAGE_BASE_OFFSET parameter (in microns) using the diagnostic
commands:
rd_image_offset wr_image_offset
A) B)

To move the image nearer the punch, add the error value to 680000. To move the image away from the punch, subtract the error value from 680000.

L UXEL P LATESETTER VOLUME 3 (1-23)

+ ERROR VALUE PUNCH END IMAGE_ BASE_ OFFSET = 680000 m ERROR VALUE 25000 m

IMAGE PLATE

START SCAN POINT

Figure 1.13 Setting the image base offset

1.8.3 Platesetters Fitted Without a Punch

These procedures apply to a platesetter without a punch and check for: Image form adjustment: see Section 1.8.1.1. Tint quality: see Section 1.8.1.2. Image skew accuracy: see Section 1.8.3.1. Edge detect function: see Section 1.8.3.2 Image start and edge accuracy: see Section 1.8.3.3 Image base offset: see Section 1.8.3.4. Image edge sensor offset: see Section 1.8.3.5.

1.8.3.1 Check Image Skew Accuracy

Use 470 mm registration pin centre points for these skew measurements as plate edge quality varies across the plate.

1. Expose a PI `tint' on a 1028 mm x 770 mm plate. 2. Measure reference lines A and B with a glass or steel ruler and a x50 eyeglass,
see Figure 1.14.

VOLUME 3 (1-24) R OUTINE MAINTENANCE

305 mm FOR B2 470 mm FOR B1

LEAD EDGE OF REGISTRATION PINS

IMAGE

PLATE

Figure 1.14 image skew check

3. Check that the difference between the two lines is less than or equal to 50
microns ( 25 microns).
30 microns.

4. Expose and measure 4 plates and check that repeatability is less than or equal to 5. A possible cause of error could be poor push bar alignment.

1.8.3.2 Check Edge Detect Function

Check the plate edge detect function as follows:

1. Reboot the Engine if the optics_mmi test patterns have been used beforehand. 2. Enter the command:
main> diagnostics/service/traverse> halt traverse>medirq

Check that the Edge Detect PCB laser beam is ON.

3. Load a plate into the drum and move the traverse by hand so that the edge
detect beam moves across the plate edge.

4. Check that the LED on the Edge Detect PCB is OFF when the beam is on the
plate and ON when the beam is on the drum.

5. Press Ctrl-c to exit medirq.

1.8.3.3 Check Image Start and Edge Accuracy

1. Expose a PI `tint' on a 1028 mm x 770 mm plate. 2. Check that the distance between the image start positions and plate edge is as
shown in Figure 1.15. Measure from the registration pins for the image top offset, and 67 mm down from the plate top edge for the image side offset position.

L UXEL P LATESETTER VOLUME 3 (1-25)

305 mm FOR B2 470 mm FOR B1

2 mm ( + 25 m) -

67 mm 1 mm (+ 25 m) -

IMAGE

PLATE

Figure 1.15 Edge detect and image accuracy

1.8.3.4 Set Image Base Offset

This procedure adjusts the non-imaged area at the top of the plate.

1. Expose a PI `tint' on a 1028 mm x 770 mm plate. 2. Check for the default imaging area shown in Figure 1.16. 3. Modify the IMAGE_BASE_OFFSET parameter (in microns) using the diagnostic
commands:
rd_image_offset wr_image_offset
A)

To move the image nearer the registration pins, add the error value to the default value. To move the image away from the pins, subtract the error value from the error value.

B)

VOLUME 3 (1-26) R OUTINE MAINTENANCE

+ERROR VALUE

IMAGE_BASE_ OFFSET = 2 mm ( + 25 m) -

- ERROR VALUE

IMAGE

START SCAN POINT

PLATE

Figure 1.16 Setting the image base offset

1.8.3.5 Set Image Edge Sensor Offset

1. Open the optics_mmi setup screen from:
main>diagnostics/service/optics/optics_mmi

2. Run a test pattern with the Scan Start position as 0 mm. 3. Eject and process the image and check that it is exactly 1 mm from the righthand
edge of the plate.

4. If it is not then find the current parameter EDGE_SENSOR_OFFSET value (in

microns) as follows:
diagnostics/log_utils/nvram> rd_edge_sensor_offset

5. 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: Repeat this command until the offset is correct.
diagnostics/log_utils/nvram> wr_edge_sensor_offset <required offset in microns>

Volume-Chapt er

PLATE HANDLING SERVICE PROCEDURES

This chapter describes how to remove and replace plate handling modules and devices.

2.1 Starting the Service Procedures

Plate handling assemblies are designed for easy removal and replacement. This chapter describes how to service the following field replaceable units (FRUs) used to convey and control plates: General Plate Handling Replacements: a general method for replacing sensors and FHMBs. Autofeeder: replacements and checks for a fully-automatic system. PTM: replacements and checks for a fully-automatic system. Engine: replacements and checks on an engine for all variants.

2.1.1 General Plate HandlingReplacements

2.1.1.1 Sensor (Reflective-Opto PCB) Removal
See Figure 2.1 and Figure 2.2.

4 4 4 4 4

Starting the Service Procedures ............................................................................... 2-1 Autofeeder Servicing ................................................................................................. 2-4 Plate Transport Module Servicing .......................................................................... 2-15 Engine Servicing ...................................................................................................... 2-27 Buffer Servicing ........................................................................................................2-57

VOLUME 3 (2-2) P LATE H ANDLING S ERVICE P ROCEDURES

BUTTON RIVET CONNECTOR PCB INSERT

SENSOR

MOUNTING

Figure 2.1 Removing a button snap rivet

SNAP RIVET CONNECTOR PCB INSERT

PUSH OUT SCREWDRIVER SENSOR MOUNTING

Figure 2.2 Removing a snap rivet

In some locations, the reflective-opto sensor is mounted using button or snap rivets that are removed as follows:

1. Release the PCB from its mounting plate by pulling out the button rivet stud

from its insert (see Figure 2.1) or pushing out the rivet insert (Figure 2.2) with the flat end of a screwdriver. use a small screwdriver).

2. Carefully disconnect the cable lead to the header connector (you may need to 3. Reconnect the lead to the new PCB. 4. Replace the new PCB by refitting the insert into the PCB, locating the PCB on its
mounting position and gently pushing in the stud. The insert splays to secure the PCB to its mounting.

2.1.1.2 Sensor (Opto-Slotted) Removal

See Figure 2.3. These sensors are positioned on a mounting bracket by a locating pin.

1. Pull off the lead connector. 2. Release the sensor by removing the 1-off, M4 fixing screw.

L UXEL P LATESETTER VOLUME 3 (2-3)

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 FIXING (M4) CONNECTOR

METAL TAB

Figure 2.3 Removing a typical opto-slotted sensor

2.1.1.3 FHMB Replacement

FHMB (1 to 4) are common assemblies that can be removed and replaced using the same procedure. For more information on variant PCB connections see: PTM: Volume 2 Section 3.3.1 Engine: Volume 2 Section 3.4.1

1. Disconnect cable ties, where appropriate. 2. Disconnect top cables (power minifit, etc). 3. Remove the 3-off Philips cover screws and remove the cover. 4. Disconnect all other cable connectors. 5. Remove the 6-off screws securing the PCB to the stand-offs. 6. Fitting the new board is the reverse of the above procedure. Make sure the
hidden cable connectors in Step 4. are fitted before fixing the cover.

7. Load the correct level of firmware on the newly-installed FHMB. All PCBs must
have the same level of firmware - if they do not match the system will not function correctly.

8. FHMB4: if you are replacing FHMB4 you must update NVRAM parameter,
FHMB_GAIN, to ensure accurate exposure calibration. Enter the folowing:
development/nvram> snv FHMB_GAIN <factory value>

where <factory value> is the value written on the replacement FHMB.

VOLUME 3 (2-4) P LATE H ANDLING S ERVICE P ROCEDURES

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.

2.2 Autofeeder Servicing

This section shows how to remove, replace and check the main FRUs on an autofeeder:

2.2.1 Accessing Autofeeder Assemblies

Figure 2.4 shows which covers are removed for accessing the main replaceable assemblies on the Autofeeder, and any screws that need removing. Avoid damaging the screw tabs at the base of the covers when moving them to a temporary location.
ELEVATOR MOTOR/GEAR ELEVATOR DIST/CONTROL PCB's INVERTER I/L CONTACTOR ABSOLUTE LIMIT SENSORS I/F CONNECTORS CHAINS

CHAIN SPRINGS/ TENSIONERS

SERVICE SIDE

DRIVE SHAFT

OUTPUT SIDE

CHAIN SPRINGS/ TENSIONERS

CASSETTE DOOR: S/W LOCKED FROM MMI BOTTOM SCREW LOCK TOP SCREW LOCK

USER SIDE

Z-DIRECTION ARM CASSETTE DOOR LOCK DOCKING MECHANISMS CHAINS

Figure 2.4 Accessing Autofeeder modules

2.2.1.1 RFI Filter Replacement

CAUTION: Do not touch the cooling fins while the elevator motor is operating.

L UXEL P LATESETTER VOLUME 3 (2-5)

See Figure 2.5.

1. Disconnect the mains supply from the PTM. 2. Remove the Elevator Control box cover, see Volume 2 Figure 3.1. 3. Remove the inverter assembly, see Section 2.2.1.2. 4. Remove the MAINS_ELV_IN cable and mark each wire. 5. Remove the RFI filter assembly. 6. Fit the replacement filter, inverter and reconnect the cables. 7. Make sure all earth bonding and cable shielding connections are correctly
refitted.

8. Reconnect the power cable to the PTM. 9. Switch on power. 10. Test elevator control by using the MMI Media Tools option to advance a cassette
from each shelf in turn.

2.2.1.2 Inverter Replacements Inverter Fault-finding

The inverter includes a number of protective functions that will trip if the conditions in Table 2.1 are detected. This causes the motor AC input to shut down and remain in that state until it is reset. An LCD display shows the appropriate error code, see Figure 2.5.
Table 2.1 Inverter error code conditions Error Type
Over Current Overload Braking Overload Overload EEPROM Error Undervoltage CT Error CPU Error External Trip USP Error Ground Fault

Displayed Code
01 to 04 E 05 E 06 E 07 E 08 E 09 E 10 E 11 E 12 E 13 E 14

Error Comment
Output of inverter is shorted, motor is locked or the load is too heavy. Motor stops. Motor overload is detected. Motor stops. Overvoltage is detected and motor stops. Motor overload is detected and mo tor stops Memory has problems due to noise or temperature. Motor stops. Decrease in DC voltage to a certain cut off point. Motor stops. Large noise source too close to the inverter. Motor stops. CPU malfunctions. Motor stops. Abnormal signal from external source cuts off motor. Power is turned on while the inverter is running. Ground fault detected between inverter and output and motor.

VOLUME 3 (2-6) P LATE H ANDLING S ERVICE P ROCEDURES

Table 2.1 Inverter error code conditions (Continued)

Input Overvoltage Thermal PTC Error E 15 E 16 E 17 Input voltage is above a certain limit. Motor stops. Temperature of inverter is too high. External thermistor is faulty. Motor stops.

ON/OFF LAMP INVERTER RUNNING LAMP RUN SETTING PARAMETER LAMP PRG

POWER DIGITAL DISPLAY Hz A FREQUENCY OR CURRENT DISPLAY LAMP

RUN
RUN KEY TO START STOP/RESET KEY

STOP RESET
MIN MAX

SETS FREQUENCY DO NOT TOUCH

FUNCTION CONTRO DO NOT TOUCH

Figure 2.5 Inverter digital display

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.

1. Disconnect the mains supply from the PTM. 2. Disconnect the filter wires, the 3-phase INV_MOTOR cable and the ELV_CRTL
cable from the inverter box, see Volume 2 Figure 3.4. Make sure each wire is marked.

3. Refit the replacement inverter box and reconnect the cables. 4. Make sure all earth bonding and cable shielding connections are correctly
refitted.

5. Reconnect the power cable to the PTM. 6. Switch on power. 7. Test the elevator control by using the MMI Media Tools option to advance
cassettes from each shelf in turn.

L UXEL P LATESETTER VOLUME 3 (2-7)

2.2.1.3 Contactor Replacement

See Volume 2 Figure 3.5.

1. Disconnect the cable connections to the contactor and mark each wire. 2. Remove the rail end-stop. 3. Slide out the contactor assembly. 4. Replace the contactor and refit the cables. 5. Switch on power and check that the elevator motor operates:
medtran> move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)

6. Open an interlocked cover to check that the motor switches off.

2.2.1.4 Elevator Control PCB Replacement

See Volume 2 Figure 3.8.

1. Disconnect the three connectors from the PCB. 2. Remove the PCB from its mounting (4-off pozidrive screws). 3. Fit the replacement PCB and the connectors. 4. Use the following diagnostics commands to check the operation of the
Autofeeder:
medtran> init

to initiate a media transport. Ensure the cassette is reversed from the feed head and the X-door is down.
medtran> move_elevator <shelf letter> (where a = 0 or top; b = 1; c = 2; d = 3; e = 4)

2.2.1.5 Elevator Distribution PCB Replacement

See Volume 2 Figure 3.1 and Volume 2 Figure 3.9.

1. Disconnect the three connectors from the PCB. 2. Scribe a line on the frame in line with the bracket to indicate the exact vertical
position of the PCB.

3. Remove the bracket and PCB (2-off Allen screws). 4. Remove the PCB from the bracket (4-off posidrives). 5. Fit the replacement PCB and reconnect the cables. 6. Use the following diagnostics commands to check the operation of the
Autofeeder:
medtran> init

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)

7. Check and align the elevator shelves, see Section 2.2.1.6.

2.2.1.6 Setting Up the Elevator Shelf/Rail Alignments

Use the following procedure to check the mechanical alignment between the

VOLUME 3 (2-8) P LATE H ANDLING S ERVICE P ROCEDURES

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.
Table 2.2 Elevator-PTM rail measurements Shelf Level (mm)
User A (top) B C D E Service

Distance (mm)
User Service

2. Measure the difference in height between the Autofeeder shelf and the PTM rail,
and enter it in the table above. in the table above.

3. Measure the distance between the Autofeeder shelf and the PTM rail, and enter it 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.
Table 2.3 Level/distance measurements - example values Shelf Level (mm) User
A (top) B C D E +0.8 +0.5 0 -0.5 -0.2

Distance (mm) Service

0 +0.5 -0.2 -1.0 -0.4

User
5.5 6.0 6.0 6.5 5.3

Service
6.0 7.0 6.5 7.0 7.5

L UXEL P LATESETTER VOLUME 3 (2-9)

DISTANCE APART = +2 mm (max) LEVEL = 1 mm

AUTOFEEDER SHELF RAIL

X-DOOR FLAP ADJUST DISTANCE

PLATE TRANSPORT CASSETTE GUIDE RAIL

Figure 2.6 Checking cassette-PTM guide rail alignment

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. Shelf B: does not require adjustment. Shelf C: does not require adjustment. Shelf D: user side, change -0.5 mm to +0.25 mm; then service side will change -1.0 mm to -0.25 mm. Shelf E: does not require adjustment but could be possibly set to +01 mm and -0.1 mm.

B) C) D)

E)

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: Elevator shelf too low then move the vane up. Elevator shelf too high then move the vane down.

Adjust so that the minimum shelf level changes on either side are within specification first of all, and then adjust the other shelves in turn. Check each shelf after the adjustment.

4 4

VOLUME 3 (2-10) P LATE H ANDLING S ERVICE P ROCEDURES

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.

7. Decide on the adjustments to achieve the distance specification. For instance,

with the measurements shown above: User Side: Shelf E has the smallest gap, so set the Shelf E gap to 1 mm. Service Side: Shelf A has the smallest gap, so set the Shelf A gap to 1 mm. If the specification cannot be achieved, then adjust the top or bottom cam follower brackets to move the elevator frame. The distance between the frame edge and the PTM skins are factory-set at 130 mm, but an on-site adjustment at the top or bottom brackets (2-off Allen screws) on either side is possible, see Figure 2.7.

8. After adjusting a bracket, ensure that all the elevator vanes clearly pass through
sensors BS30 to BS34. On completing the adjustments, move the elevator to all shelf positions and check that they are not obstructed.

9. Recheck that all the shelves conform to the level specification in Step 6. 10. Ensure that all the screws are tightened.

L UXEL P LATESETTER VOLUME 3 (2-11)

PTM SKIN

FRAME EDGE

NOTE: PTM SKIN TO FRAME EDGE = 130mm

CAM FOLLOWER BRACKETS

Figure 2.7 PTM to elevator frame edge distance

2.2.1.7 Cassette Door Lock Replacement

Remove and replace the lock as follows:

1. Remove the 2-off pozidrive screws holding the lock assembly to a bracket. 2. Disconnect the 4-off wires to the lock and refit them to the new lock, see Volume
2 Figure 3.11.

3. Replacement is the reverse of the removal. 4. Check that the lock unlatches from MMI control.
If the door is jammed shut and unable to open under MMI control, a special triangular key is available from Schmersal for manually releasing the lock. The procedure to manually release the lock is:
A)

Move the elevator down to its lowest position:

move_elevator a

B) C)

Remove the cover underneath the cassette door. Reach up inside (with the right hand), locate the tool in the lock and rotate anticlockwise until the door opens. Once the door is open, relocate the key into the lock and turn clockwise to reset the lock.

D)

2.2.1.8 Docking Lamp Replacement

The docking lamp (type: 28 V, 40 mA) is removed and replaced as follows:

VOLUME 3 (2-12) P LATE H ANDLING S ERVICE P ROCEDURES

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).

2.2.1.9 Docking Sensor Replacement

Sensors (BS77/78) are removed and replaced as follows:

1. Open the cassette door. 2. Remove the docking buffer block (3-off M4 Allen screws) 3. Disconnect the sensor inline connector. 4. Unscrew the sensor from the block. 5. Replace the sensor making sure that it is flush with the buffer surface. 6. Re-assemble the sensor and block, and refit it to the platesetter. 7. Check that the sensor and lamp operate correctly.

2.2.1.10 Z-Direction Control Removal

See Volume 2 Figure 3.1 and Volume 2 Figure 3.13.

1. Open the cassette door from the MMI Cassette Change procedure. 2. Switch off the platesetter. 3. Remove the cover bracket on the user side of the Autofeeder. 4. Remove the buffer block on the door frame (3-off M4 Allen screws). 5. Remove the Z-direction arm cover bracket. 6. Disconnect the motor (BM28). 7. Disconnect the sensors BS63 and BS70. 8. Remove the 2-off M4 caphead screws holding the assembly to the chassis. 9. Lift out the assembly.

2.2.1.11 Z-Direction Control Replacement

1. Replacement of the assembly is the reverse of the removal. Note: connect the
sensors before refitting the assembly.
actuators> set bm28 on sensors> read_con ip actuators> set bm28 off sensors> read_con ip

2. Check the operation of the arm using the commands:

Check that the sensors switch.

2.2.1.12 Absolute Limit Safety Switch Replacement

1. With the platesetter powered off, remove the cover on the service side of the
autofeeder to access the two switches.

2. Remove the 2-off M3 retaining caphead screws on the switch.

L UXEL P LATESETTER VOLUME 3 (2-13)

3. Disconnect the two cable connections (ELV_CON_24V) inside the switch. 4. Fit the replacement switch, connect the two cables and the switch cover. Ensure
the switch is reset (yellow button in its outer position).

5. Switch on the platesetter.

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.

6. Check the operation of the switch as follows:

A)

Visually check that the two absolute limit sensors on the Autofeeder are reset (button pulled out).. Enter the following command to move the elevator (where a = top shelf and e = bottom shelf):
service/medtran> move elevator <e>

B)

WARNING: Understand the dangers of moving parts on the Autofeeder.

C) D) E)

While the elevator is moving, trip one of the limit sensors by hand. Check if MMI error 1351 appears and the inverter displays error 01. Reset the inverter (press Reset), reboot the platesetter and reset the limit sensor. Repeat steps 2) to 5) for the other limit sensor.

F)

2.2.1.13 Elevator Motor (BM26) Replacement

See Volume 2 Figure 3.1.

1. Disconnect the mains supply from the Autofeeder to the PTM. 2. Disconnect the cable, INV_MOTOR, from the contactor. 3. Remove the 4-off M23 motor bolts from the gearbox coupling. 4. Lift out the motor and the cable assembly. 5. Fit the replacement motor using the same bolts. 6. Reconnect the cable to the contactor and reconnect the power. 7. Check the elevator operation by selecting different cassettes from the MMI.

2.2.1.14 Chain Tensioner Spring Replacement

See Volume 2 Figure 3.17 and Volume 2 Figure 3.18.

1. Remove the two covers on the service and user sides. 2. From Main Diagnostics, select the top shelf to move the elevator to its lowest
position:
medtran> move_elevator b

3. Disconnect power to the Autofeeder by removing the power connector lead to

the PTM.

VOLUME 3 (2-14) P LATE H ANDLING S ERVICE P ROCEDURES

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.
CAUTION: Do not use the MOVE_ELEVATOR command for this operation.

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)

Figure 2.8 Inserting safety blocks

7. Replace each spring, one at a time, using the following method:

A)

Remove the split pins, remove the link plate and pull out the pin link between the two bushes. Remove the spring from the bush. Fit the new spring into the free bush. Replace the link and split pin.

B) C) D)

8. Raise the elevator by turning the motor cooling fan clockwise until it is clear of
the blocks, and then remove the blocks.

9. Reconnect power to the Autofeeder. 10. Use the following diagnostics commands to check the operation of the
Autofeeder:
medtran> init

L UXEL P LATESETTER VOLUME 3 (2-15)

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)

2.3 Plate Transport Module Servicing

PTM assemblies on and around the feed head are very precisely adjusted to ensure continuous removal of plates and paper without the risk of media jams. During a parts replacement, make sure the procedures in this chapter are followed carefully so that PTM is setup for correct operation.

2.3.1 Accessing PTM Assemblies

The main PTM assemblies are accessed from the covers shown in Figure 2.9.
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

RELEASE SCREW AT USER END AND SLIDE OUT UNDER TRAY TO ACCESS ASSEMBLIES BOTTOM SCREW LOCK NOT LOCKED

BS76 DIVERTER STACK INCREMENT RETARD PAD X-DIRECTION DOOR SENSORS/MOTORS

INTERLEAF DOOR OPEN

Figure 2.9 Accessing PTM assemblies

VOLUME 3 (2-16) P LATE H ANDLING S ERVICE P ROCEDURES

2.3.2 PTM Sensor Replacements and Setups

Section 2.1.1.1 and Section 2.1.1.2 describes the general replacement method for opto-reflective and opto-slotted sensors.

2.3.2.1 BS55 Sensor Setup

This procedure is used to set up the paper detect sensor (BS55) after it has been replaced. This sensor is mounted below the post-diverter guide plate, see Volume 2 Figure 3.39. It detects paper stuck to the underside of the plate that has not been removed from the feed head. It has a 3/4 turn adjustment potentiometer that is rotated between 11 oclock (minimum sensitivity) and 4 oclock (maximum sensitivity) positions. Under normal operation, the plate or paper passes within 20 mm of the guide plate. Since the adjusting pot is inaccessible from the top you will need to lift the guide plate to carry out the procedure below. Items required: small strip of plate and interleaf paper.
CAUTION: Lifting the guide plate with the machine powered on could damage the sensors 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.
diagnostics/service/sensors> read_con ip

4. Power up the sensor using the command:

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. to the guide.

7. Raise the plate 20 mm above the guide plate, keeping the printing plate parallel 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.

2.3.2.2 BS51 Sensor Setup

This procedure is used to set up the paper detect sensor (BS51) after it has been replaced. This sensor is mounted above the post-diverter guide plate on the PTM frame crossbar, see Figure 2.10. It detects paper stuck to the top of the plate that has not been removed by the feed head. It has a 3/4 turn adjustment pot that can be rotated from approximately 11 oclock (minimum sensitivity) to 7 o'clock (maximum sensitivity). Items required: small strip of plate, small spacer of magnetic metal 10 mm x 9 mm, and interleaf 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.
diagnostics/service/sensors> read_con ip

2. Power up the sensor using the command:

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

SENSOR BRACKET

10mm SPACER

Figure 2.10 BS51 setup - positioning the spacer

2.3.3 X-Direction Door

2.3.3.1 X-Direction Door Replacement
See Volume 2 Figure 3.31.

1. Access the X-direction door assembly. 2. Move the bottom shelf on the elevator to line up with the feed assembly using
the command below or the MMI menu:
service/medtran>move-elevator e

3. Make sure the X-door is horizontal using the command:

service/actuators> set bm27 off

4. Switch off power to the Engine. 5. From the user side, disconnect the motor (BM27) cable and unbolt the motor
(BM27) bracket.

6. Holding the flap, tip the door 45 to avoid damage to the sensors and pull it
towards the user end with care. care with the sensor vane.

7. Lift out the assembly (the bearing will slip out of the sensor end bracket). Take 8. Complete the reverse of the removal procedure above. 9. Actuate the flap using the command:
service/actuators> set bm27 on

L UXEL P LATESETTER VOLUME 3 (2-19)

service/actuators> set bm27 off

10. You may need to adjust the horizontal position by moving the sensor bracket,
and the vertical position by moving the sensor vane.

Vertical Position:
The flap should be vertical or slightly away from the elevator.

Horizontal Position:
The flap should be horizontal or slightly above the cassette forward top plate, see Volume 2 Figure 3.33. Ensure it is below the cassette forward arms.

2.3.3.2 Motor (BM27) Removal

1. Remove the assembly, as explained above. 2. Remove the circlip from the end of the shaft. 3. Slide the motor/gearbox from the shaft.

2.3.4 Cassette Forward

See Volume 2 Figure 3.32.

2.3.4.1 Cassette Forward Removal

4. While power is on, lift the X-direction door to the vertical position using the
command:
service/actuators> set bm27 on

5. Ensure the elevator has an empty shelf at the feed level. Use the command:
service/medtran> move_elevator <shelf letter>

1. Access the cassette forward assembly, see Figure 2-2.9. 2. Release the belt tension by loosening the M6 caphead screw at the service side. 3. Mark the position of the assembly in the frame. 4. Disconnect cables to the following devices:
A) B) C)

BM20 (cassette forward motor) BS41 (cassette forward limit sensor) BS42 (cassette reverse limit sensor).

5. Remove the 8-off M5 top plate screws holding the assembly to the mounting
frame.

6. Lift out the assembly.

2.3.4.2 Cassette Forward Replacement

7. Line up the assembly with the frame marks made in step 5 above. 8. Secure the assembly to the frame. 9. Put a screwdriver behind the eccentric as an aid for re-tensioning. 10. Tension the belt until it is difficult to twist more than 180 degrees. You can
access the belt through the top plate holes.

VOLUME 3 (2-20) P LATE H ANDLING S ERVICE P ROCEDURES

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

2.3.4.3 Motor (BM20) Removal

1. Remove the cassette forward assembly, as explained above. 2. Remove the 4-off M4 caphead screws securing the motor/gearbox. 3. Remove the drive wheel from the gearbox shaft by releasing the M19 screw.

2.3.4.4 Drive Belt Removal

1. Remove the circlip. 2. Loosen the M19 torque nut and withdraw the cassette arm and shaft from the
drive wheel.

3. Loosen the torque nut on the motor shaft. 4. Remove the 4-off 4 mm caphead screws holding the motor to the plate and
remove the motor.

5. Remove the belt by passing it over the idler wheel. 6. Fit the replacement belt over the drive wheel. 7. Insert the drive wheel into the housing, re-tighten the torque nut and re-fit the
circlip.

8. Re-fit the pulley housing assembly to the plate. 9. Fit the replacement belt.

2.3.5 Stack Increment

See Volume 2 Figure 3.34.

2.3.5.1 Stack Increment Removal

1. Switch off Engine power. 2. Access the stack increment assembly. 3. Disconnect cables to the following devices:
A) B) C)

BM21 (stack height) BS47 (stack height position) BS61 (stack height top limit).

L UXEL P LATESETTER VOLUME 3 (2-21)

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 crossbar.

5. Tip the assembly away from the cassette centering locators. 6. Lift out the assembly.

2.3.5.2 Stack Increment Replacement

1. Complete the reverse of the removal procedure. 2. Ensure that the lift bar leadscrew bearings are fully seated (that is, not restrained
vertically).

3. Manually lower the stack by moving the drive belt to ensure that the sensor
vane is between sensors BS47 and BS61

4. Switch power on. 5. Pull the cassette forward using the command:
service/medtran> load_cassette

6. Run the stack height routine using the command:

service/medtran> prepstack

7. Check that the cassette plinth is horizontal (+ 0.2 mm). 8. Check the stack set height.

2.3.5.3 Motor (BM21) Removal

1. Remove the M16 retaining nut on the motor shaft and withdraw the wheel from
the shaft.

2. Remove the 4-off M3 caphead screws retaining the motor/gearbox to the

support bracket and replace.

3. Adjust the slide motor fixings to tension the 410 belt.

2.3.5.4 Drive Belts Removal

1. Remove the stack increment assembly, as shown above. 2. Drive the stack increment up to set 4 mm spacing at both ends. 3. Loosen the 4-off M3 caphead screws retaining the motor to the mounting plate. 4. Detach the small and large belts and replace. 5. Check for parallel operation at each end. If there are signs of misalignment,
loosen the torque nut and adjust.

2.3.6 Feed Head

See Volume 2 Figure 3.35.

2.3.6.1 Feed Head Removal

1. Ensure that the nudger is up using the Main command:

VOLUME 3 (2-22) P LATE H ANDLING S ERVICE P ROCEDURES

service/actuators> set bm23 on

1. Switch off the platesetter. 2. Access the feed head assembly. 3. Disconnect cables to the following devices:
A) B) C) D) E) F) G)

BS43 (cassette empty) and p-clip BS45 (nudger down) BS46 (nudger up) BS47 (stack height position) BS48 (nudger detect) BM22 (nudger and takeaway) BM23 (nudger lift).

4. Pull all connector cables through the central hole.

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. pins.

6. Hold the assembly by the two motors and lift away from its two locating dowel 7. Place the assembly on a clean surface, ensuring that it is not resting on the
nudger detect bracket.

2.3.6.2 Feed Head Replacement

8. Place the assembly on locating pins, ensure the cables are clear and bolt to the
support backplate. assembly.

1. Ensure all the cables pass through the central hole of the PTM and feed head 2. Replace all connectors. 3. Make sure the mylar strips are towards the Engine to allow the plates to feed. 4. Make sure BS46 (nudger up limit) is at the 12 o'clock position. 5. Switch on power. 6. Enter the command:
service/medtran> init

and:
service/medtran> load_cassette (with a 1030 x 800 plate).

7. Check the BS48 (nudger detect) setting by entering:

service/sensors> read_con ip

The sensor should detect plates resting on the cassette edge.

L UXEL P LATESETTER VOLUME 3 (2-23)

Stack Height Position Check

Use this procedure to check if the top plate surface on a cassette stack is level with the lead edge guide on the retard assembly. Once an offset has been entered for one plate thickness, NVRAM parameters for all the other plate and paper thickness are automatically adjusted.

1. Remove the lid from a selected cassette. 2. From the MMI, advance a cassette to the feed head with any plate height or size. 3. From Main Diagnostics, display the current offset by entering:
diagnostics/service/medtran> set_stack_height

4. Enter stack height as:

diagnostics/service/medtran> set_stack_height 0

This sets the current reference height to 0 and raises the plate stack to the lead edge guide and lifts the nudge roller clear of the top plate.
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.

TOP PLATE

LEAD EDGE

PLATE STACK STACK INCREMENT

RETARD ASSEMBLY

Figure 2.11 Checking the stack height

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.

2.3.6.3 Motor (BM23) Removal

1. Remove the feed head assembly, as described above. 2. Remove the 4-off M3 caphead screws holding the motor/gearbox to the
mounting end plate. the new motor.

3. The nudger lift cam is retained on the motor shaft by a pin. Replace the cam on

2.3.6.4 Motor (BM22) Removal

1. Remove the feed head assembly, as described above. 2. Make a note of the chain tension. 3. Remove the 4-off M3 caphead screws holding the motor/gearbox to the
mounting end plate.

4. Remove the gear from the motor shaft by loosening the grubscrew with a 1.5mm
Allen key. Replace the gear on the new motor and tighten fully to avoid slippage.

5. Re-tension the chain from the slotted holes in the mounting end plate.

2.3.7 Retard Pad

See Volume 2 Figure 3.37.

2.3.7.1 Retard Pad Removal

1. Access the retard pad assembly. 2. Move the retard pad to the up position using the command:
service/actuators> set bm25 on

3. Switch off power. 4. Remove the feed head, see Section 2.3.6. 5. Remove the pre-diverter guides, see Section 2.3.8. 6. Disconnect cables from the following devices:
A) B) C) D)

BM25 (retard drop motor) BS56 (retard up) BS57 (retard down) BS65 (cassette at nudger).

L UXEL P LATESETTER VOLUME 3 (2-25)

NOTE: Do not remove the retard interface plate from the cross-bar assembly. This is factory-set.

7. Remove the 2-off M4 screws to remove the retard pad only. 8. Remove the 4-off M4 caphead screws on the outside of the mounting plate. 9. Lift the assembly straight up from the machine.

2.3.7.2 Retard Pad Replacement

1. Complete the reverse of the removal procedure. 2. Check that the retard pad is free to move up and down using the command:
service/actuators> set bm25 on service/actuators> set bm25 off

3. Check that the pre-diverter guides are correctly located. 4. Check that the pre-diverter guides are flush with one another and below the
leading edge guide.

2.3.8 Interleaf Diverter and Drive Roller

See Volume 2 Figure 3.38.

2.3.8.1 Interleaf Diverter Removal

1. Access the diverter assembly. 2. Release the bearing retainer at the user end and lock the retainer clear of the
bearing. weight.

3. Remove the M3 screw holding the counterbalance weight and remove the 4. Slide the assembly towards you until the bearing drops out. Slide the bearing off
the shaft.

5. Lift up the hinged sensor (BS51) so that its clear. 6. Slide the shaft to uncouple it from the solenoid. Leave the solenoid in position, if
possible.

7. Slide the shaft off the motor drive and lift out.

2.3.8.2 Interleaf Diverter Replacement

1. Slide the bearing (user side) end through the end plate hole first and slide back
to couple to the solenoid.

2. Slide the bearing onto the shaft and lock the retainer. 3. Replace the counterweight. 4. If the solenoid was replaced or moved, secure the bracket. 5. Actuate the solenoid to check its operation using the command:
service/actuators> set bv20 on

VOLUME 3 (2-26) P LATE H ANDLING S ERVICE P ROCEDURES

2.3.8.3 Interleaf Drive Rollers Removal

1. Access the drive roller assembly. 2. Remove the diverter and post-diverter guides. 3. Remove the drive roller assembly from the service side:
A) B) C)

Loosen the 4-off M3 slot screws retaining the motor on the service side. Remove the drive belt. Remove the pulley from the drive roller and release the interleaf steady bracket.

4. Remove the bearing retainer end plate at the user end (2-off M3 cap heads). 5. Loosen the lower guide plate (below rollers). 6. From inside the interleaf bin, pull out the drive roller assembly from the PTM
feed frame.

2.3.8.4 Interleaf Drive Roller Replacement

1. Complete the reverse of the removal procedure. 2. Check that all the plate guides do not touch the roller segments. 3. Bias the nip roller with the steady bracket. Ensure that there are no gaps
between the segments.

2.3.9 Transport Plate Guides

See Volume 2 Figure 3.39.

2.3.9.1 Pre-Diverter Plate Guide Removal

This guide is made up of two separate plates, lefthand (LH) and righthand (RH), held by fixing brackets.

1. Remove the 3-off M4 caphead screws on the outside of each guide. 1. Loosen the 2-off wing nuts and M6 screws holding the guides to their fixing
brackets.

2. Lift out the LH and RH plates from the PTM. 3. Check that the plate guides do not have an aluminium build-up. If necessary,
polish with a metal polish or Autsol. smooth surface for the plate.

4. When replacing the two plates, make sure they are even at the centre to ensure a 5. Advance a plate to the feed head and check if BS50 and BS49 operate correctly. 6. Check that the guide is subflush with the diverter (when down), see Figure 2.12.
You may need to insert washers under the corner fixings of the guide plates to adjust the height slightly.

L UXEL P LATESETTER VOLUME 3 (2-27)

DIVERTER SUBFLUSH AND IN PRE-DIVERTER GUIDE RECESS

DIVERTER

PRE-DIVERTER GUIDE

Figure 2.12 Diverter subflush with guide plate

7. Check the operation of the diverter while feeding plates and paper.

2.3.9.2 Post-Diverter Plate Guide Removal

1. Switch off power to the machine. 2. Remove the 2-off M4 pozidrive screws holding the plate to the frame and lift out
the plate.

3. Disconnect the sensors (BS55 and BS59). 4. Replacement is the reverse of removal.

2.3.9.3 Engine Interface (Output) Plate Guide Removal

1. Remove the 2-off pozidrive screws. 2. Lift out the guide assembly with its sensor (BS52). 3. Disconnect the sensor cable. 4. Replacement is the reverse of removal.

2.4 Engine Servicing

2.4.1 Accessing Engine Assemblies
Figure 2.13 shows which covers are removed for accessing the main replaceable assemblies on the Engine. See Volume 3 Section 3.1 for details on how to replace the traverse FRUs (Edge Detect PCB, etc).

VOLUME 3 (2-28) P LATE H ANDLING S ERVICE P ROCEDURES

LOADING PLATFORM MECHANISMS

SERVICE SIDE

REG PIN OPTO ISOLATION I/F CONNECTORS FILTER BOX FHMB 1 AIR KNIFE SWING ROLLER MOTOR INTERLOCK BOX PUSH BAR MECHANISMS DISTRIBUTION PCB'S TRAVERSE PCB TRAVERSE CARRIAGE MECHANISMS MIXER FAN EDGE DETECT FAST PHOTO DETECT

INPUT SIDE FHMB 4 INPUT MODULE UMBILICAL CABLE

OUTPUT SIDE FHMB 4 OUTPUT MODULE SWING ROLLER MODULE REGISTRATION MODULE

USER SIDE VACUUM SOLENOIDS COMPRESSOR BOX PERISCOPE MECHANISMS PUSH BAR PUNCH

SCREW LOCKED NOT LOCKED

Figure 2.13 Accessing Engine assemblies

2.4.1.1 Removing the Drum End Caps

Figure 2.14 shows how the drum end cap is removed from the drum casting on the user side. Removing the user side end cap allows access to the traverse carriage and the spinner mirror.

L UXEL P LATESETTER VOLUME 3 (2-29)

Figure 2.14 Removing the drum end cap (user side)

2.4.2 Loading Platform

The loading platform for the B1 and B2 variants are similar for removal and replacement.

2.4.2.1 Loading Platform Removal (Manual)

This is a two-man procedure. See Figure 2.15.

Removing the B2 Top Input Cover:

1. Remove top covers and the interlock switch (2-off pozi-screws). 2. Remove the 4-off pozi-screws holding the cover to the frame at each side. 3. Remove the two front cover trims by pushing down on the recessed clips with a
small screwdriver to release the trim.

4. Remove the cover by lifting up and tilting back to unclip it from the frame.

Removing the B1 Top Pod Cover:

1. Remove the two side doors. 2. Remove the 6-off pozi-screws holding the pod to the Engine. 3. Push the pod upwards from the back and remove horizontally so as not to
damage the input rollers.

VOLUME 3 (2-30) P LATE H ANDLING S ERVICE P ROCEDURES

COVERS REMOVED

B2 - REMOVE TOP INPUT COVER

2
COVER REMOVED

B1 - REMOVE TOP POD COVER

Figure 2.15 Removing the top input covers

Removing the Platen:

1. Remove the 4-off pozi-screws holding the platen to the frame at each side. 2. Lift out the platen to access motors and sensors. If you are careful, you will be
able to lift out the platen without disconnecting any cables. Rest the platen on wooden blocks to avoid straining cables.

3. Remove the cable ties at the user end. 4. Replacement is the reverse of removal. 5. Check the operation of the module by loading a plate and observing its
transport into the drum.

L UXEL P LATESETTER VOLUME 3 (2-31)

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.

2.4.3 Input Module

2.4.3.1 Input Module Removal (All Variants)
See Volume 2 Section 3.4.2.2. The input module is removed as a complete assembly. This is a two-man operation.

1. Open the top cover on the Engine (PTM side). 2. Manual and Semi-Automatic only: remove the front hood above the platen (2-off
screw).

3. Manually move the push bar down into the drum. 4. Manual and Semi-Automatic: remove the top input cover by disconnecting the
interlock switch and removing the 4-off side pozi-screws.

5. Remove the cover by lifting up and tilting back to unclip it from the frame. 6. Disconnect the following cables:
A) B) C)

BS1 (input entrance) - PL4, Sensor Distribution PCB. BS2 (input exit) - PL3, Sensor Distribution PCB. BM1 motor cable from FHMB(1), PL15, or from the inline connector at the motor.

7. Remove the 4-off M5 Allen screws on each side holding the module mounting
bracket to the drum casting.

8. Lift out the module. 9. Replacement is the reverse to removal. Fit the assembly so that the bracket is
inline with the drum.

2.4.3.2 Roller and Drive Belt Removal

NOTE: Rollers and belts on the input and output modules can be replaced in-situ without removing the module.

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.

2. Lift out the roller.

VOLUME 3 (2-32) P LATE H ANDLING S ERVICE P ROCEDURES

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.

2.4.4 Output Module

2.4.4.1 Output Module Removal
CAUTION: The output module is easily twisted once it is outside the frame. Handle the module with care.

Fully-Automatic:
The output module is removed as a complete assembly to access the punch, registration 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.
A) B) C)

4. Disconnect cables to the following devices:

BS4 (output entrance) BS5 (output exit) 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)

OUTPUT MOUNTING BRACKET

TOP VIEW (SERVICE SIDE)

OUTPUT SUPPORT BRACKET (PART OF ENGINE FRAME)

OUTPUT SIDE PLATE (PART OF OUTPUT MODULE) FIXING SCREW (MANUAL/SEMI SET UP POSITIONS) HEIGHT ADJUSTER

Figure 2.16 Output module - fixing points

Semi-Automatic and Manual:

It should not be necessary to remove these output modules for field servicing unless access to the swing roller or registration module is required.

1. Complete steps 1 to 5 for the Fully-Automatic machine above. 2. Replace the module but do not tighten the top 4-off fixing screws. 3. Check that the rollers at the drum end are not skewed. 4. Tighten the top fixing screws. There is no height adjustment for these variants.

2.4.4.2 Output Guide Removal

The output module includes a plate output guide that can be removed separately to access the punch assemblies and RFI box Distribution PCBs.
1. Remove the 2-off M5 Allen screws attaching the guide to the output module. 2. Detach the BS5 sensor and lift out the guide.

2.4.5 Transport Push Bar (Mark 2)

2.4.5.1 Removing the Push bar
See Figure 2.17.

1. Switch off power and open the two covers at each side of the Engine. 2. Detach the cable connector to the push bar motor assembly.

VOLUME 3 (2-34) P LATE H ANDLING S ERVICE P ROCEDURES

3. Allow the bar to move to the bottom of the drum.

Insert a protective plate under the push bar to prevent damage.

4. Remove the roller plates from both ends (2-off M6 pozi-screws). 5. Lift/slide out the complete assembly from the drum to carry out any servicing,
as required.
WHEEL ASSEMBLY DRIVE SHAFT SPRING SHOE

SPUR GEAR PITCH RING ASSEMBLY ROLLER PLATE NIP ROLLER ROLLER PLATE MOTOR END PLATE SUPPORT BAR HOME SENSOR (ON DRUM) BLANKING BRACKET

DRIVE SHAFT

HUB SPUR GEAR PITCH RING V3 ASSEMBLY PITCH RING BEARING STUB SHAFT GEAR MOTOR MOTOR MOUNTING BRACKET

Figure 2.17 Transport push bar (Mark 2)

Replace the Spring Shoes

NOTE: Spring shoes should be replaced during a scheduled 12 month service visit.

See Figure 2.17.

1. Remove the push bar.

L UXEL P LATESETTER VOLUME 3 (2-35)

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.

2.4.5.2 Replacing the Push Bar

See Figure 2.17.

1. Make sure the rings on both sides are clean 2. Locate the push bar so that the trailing edge of the support bar is inline with the
centre scribed lines at each end of the drum.

3. Ensure that the pitch ring bearing is inserted inside the drum groove. 4. Refit the roller plates at the motor end. Grip the roller plate so that it fits tightly
against the drum before securing.
NOTE: Only one of the plate wheels will be in contact with the drum as the bar moves around the drum.

5. Attach the motor umbilical cable.

Aligning the Push Bar

See Figure 2.18.

6. Visually position the back of the push bar as near as possible to the scribed line. 7. If there is a small conformance error (less than one tooth) then adjust the track at
the service side to line up the push bar to the scribed line. Loosen the M4 retaining screw at the end of the track direction that needs to be moved, see Figure 2.18. tighten the retaining screw to ensure that there is no lateral movement. securely in place.

8. Carefully tap the gear segments to move them in the required direction and 9. Tap all the segments around the drum with a light hammer to ensure they are 10. Check the user end for a conformance error and adjust the track. 11. Tighten the segment retaining screw to ensure there is no movement.

2.4.5.3 Setting up the Push Bar

1. Obtain an 0.15 mm thick plate and measure its width and height, for example,
510 mm (width or lead edge) and 400 mm (height).

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

5. Check if the plate has reached the registration pins. 6. Keep increasing the offset until the plate conforms to the drum surface without
any deformation at the pins or the push bar spring shoes. Section Aligning the Push Bar above).

7. If conformance is different at each side of the plate, align the push bar (see 8. Reconnect the mains cable to the compressors.

2.4.6 Drum Gear Segments

This procedure applies to gear segments used by both types of push bars.

2.4.6.1 Gear Segment Replacement

See Figure 2.18. Gear segments with nylon spur teeth are fitted around the drum edges for the push bar gear drive. There are 10 segments each side of the drum and each segment has 23 teeth.

1. Remove the M4 Allen screw from the nearest retainer and lift out the retainer.

Make sure the metal insert between the screw and the gear segment is not lost.
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.

2.4.7 Punch, Registration and Centerer (Billows)

2.4.7.1 Accessing Punch Assemblies
You can optionally access punch assemblies for servicing, without having to remove the complete punch from the machine: centerer, punch and registration motors centerer home sensor (BS14). Remove the complete assembly (punch, centerer and registration) from the machine if you have to: replace punch pins, dies and guides (this is not recommended as a field replacement - refer to FFEI (UK) Customer Support) replace the centering side detect sensors (BS12/13) replace the plate in punch (BS3) sensor fit a new punch option. Accessing punch assemblies for complete removal or servicing on the machine will require you to initially complete the following procedures:

1. Lower the Buffer to its service position, see Section 2.5.1. 2. Remove the rear stretcher panel on the Engine. 3. Remove the output module, see Section 2.4.4.1.

2.4.7.2 Complete Punch Removal

See Volume 2 Figure 3.60.
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.

Accessing the Assembly

See Figure 2.19 showing how the punch is removed. The complete assembly sits on two dowels fitted to the drum casting which allow the assembly to be accurately located. Remove the complete assembly as follows:

1. While the machine is switched on:

Make sure the punch pins are retracted (disengaged) using the command:
service/actuators> set bm4 on service/actuators set bm4 off

Move the traverse to the user end.

2. Lower the Buffer to its service position, see Section 2.5.1.

VOLUME 3 (2-38) P LATE H ANDLING S ERVICE P ROCEDURES

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 2off 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 .

M6 BOLTS M6 BOLTS M6 BOLTS M6 BOLTS LOWER BEAM SUPPORT DRUM CASTING DOWEL LOWER BEAM SUPPORT DOWEL

SERVICE SIDE PLAN VIEW OF DRUM CASTING PLAN VIEW OF PUNCH

LOWER BEAM SUPPORT LOCATION FOR LIFTING HANDLE LIFTING HANDLE

LOCATION FOR LIFTING HANDLE

LOWER BEAM SUPPORT

PUNCH (USER END)

Figure 2.19 Removing the punch assembly

L UXEL P LATESETTER VOLUME 3 (2-39)

Removing the Assembly

See Figure 2.19.

7. Disconnect the following sensor and motor cables to the punch:

A) B) C) D)

punch motor and 2-off sensors (service side) registration motor and 2-off sensors (rear of Engine) centering motor and 3-off sensors (rear of Engine and both ends) Plate in punch sensor. Screw the two lifting tools (part no. 7A03809) into the assembly lifting points shown in Figure 2.19 and lock into position. Remove the 8-off M6 bolts set in pairs. Using one person at each end, lift out the assembly. Once free of the locating dowel pins, lift the user end out first. Check that the two dowels are still in position in the drum.

8. Remove the punch assembly from the drum as follows:

A)

B) C)

D)

9. The complete assembly can be serviced by laying it between the two cutouts on
the wooden transit fittings used for the Autofeeder.

2.4.7.3 Complete Punch Replacement

1. If you are fitting a new punch option or complete assembly, check that it has not
been damaged during transit.

2. Position the new punch on the dowels (they should fit through the guide holes).
The punch motor will be part of the assembly which makes this operation more awkward. Avoid knocking the carriage flywheel. outwards.

3. Screw in (but do not tighten) the 8-off M6 bolts from the middle of the punch 4. Check that the setback distance is 1 mm (+0.2/-0.0 mm), see Figure 2.20.

VOLUME 3 (2-40) P LATE H ANDLING S ERVICE P ROCEDURES

SET BACK DISTANCE (1 mm)

LOWER BEAM

UPPER BEAM LATERAL DIRECTION

FEET PLATE DIRECTION

DRUM FACE

Figure 2.20 Punch setback distance

If the setback distance is incorrect then:

A) B) C) D)

measure the incorrect distance remove the punch from the drum mark the lateral position of the feet before loosening. adjust the position of the two outer punch feet (fastened by 2-off M4 panhead screws) to achieve the correct distance. replace the punch, partially tighten the M6 bolts and recheck the distance.

E)

5. Once the setback distance is correct, finally tighten the M6 bolts from the centre

outwards. Do not overtighten the bolts - the aluminium fixing hole threads in the drum are easily damaged.

6. Reconnect all cabling on the service side and the registration/centerer motors. 7. Remove the lifting tools. 8. Switch power on and halt the reset at the second Control-C message on the
MMI.

9. Check that the punch motors and sensors operate. 10. Re-assemble the machine.

2.4.7.4 Punch Adjustments and Checks

Visual plate checks are recommended after approximately 35,000 punch operations have been completed. Check the NVRAM parameter for the current

L UXEL P LATESETTER VOLUME 3 (2-41)

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.

Visual Plate Punch Check

1. Discuss with the customer any issues or problems that have appeared since the
last service visit.

2. Load a large plate (1030 x 800 mm, minimum) and expose with a 50% tint image. 3. Punch the plate manually using the command:
set bm4 on

Make sure the pins are retracted before ejecting the plate:
set bm4 off

4. Place the exposed plate on a flat surface and check the following:
A) B)

Punch crops are centred, see Volume 3 Figure 1.8.2.3. Punch crops are the correct depth: standard punch depth at 12 mm, custom at 11 mm crops are equal depth when measured between left and right (specification is 50 microns) crops are cleanly cut without debris in corners or burrs. plate lead edge to the image start position is inside the specification, see Volume 3 Section 1.8.3.3. 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.

Punch Mechanism Check

This procedure is carried out after the complete assembly has been replaced.

1. Lower the Buffer and remove the output module to access the drum side of the
punch motor.

2. Remove the shoulder screw (M5) and note the washer configuration. 3. Manually move the actuating arm and check if the mechanism is tight to move.
(Do not force the lever arm or the pins will drop out too far from the guides. The limit of movement is set by the tab flag in the opto-slotted sensor. The lever should be free moving.

4. Replace the shoulder screw. 5. Power up the machine. 6. Use Main Diagnostics to check the punch operation:
service/actuators> set bm4 on (to punch) and off (to retract)

4 4 4 4 4

VOLUME 3 (2-42) P LATE H ANDLING S ERVICE P ROCEDURES

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 nonconcentric pins/dies.

Registration Mechanism Check

This procedure is carried out after the complete assembly has been replaced.

1. Operate the registration pins:

service/actuators> set bm5 on and off

2. Check that the spring on the actuating push/pull rod is not deflecting,

indicating that it is not binding. Use diagnsotics to repeatedly retract/extend the pins.

Centering Mechanism Check

This procedure is carried out after the complete assembly has been replaced.

1. Check for a small amount of free movement of the two centering rails
underneath the centering motor.

2. Re-fit the output module and Buffer. 3. Run plates through to the Buffer and check the following:.
A) B) C) D)

Push bar alignment and plate skew. Plate conformance, see Section 2.4.5.3. Traverse image centre position. The plate is not damaged by the punch or centering mechanisms (plate edge damage). Punch chad is passing into the tray correctly and is not jamming or falling into the drum.

E)

Repack the removed punch assembly in the replacement crate, making sure it is secure and does not move during transit.

2.4.7.5 Punch Pin Checks

NOTE: Use this procedure to check the pins for mechanical operation. Refer to Fujifilm Customer Support for more information on removing pins, dies and guides if there is a problem in setting up the mechanism.

Adjust Punch Pins

See Figure 2.21.

1. Switch off power to the platesetter. 2. Remove the operating arm to the motor shaft shoulder bolt by first loosening the
bolt grub screw.

L UXEL P LATESETTER VOLUME 3 (2-43)

BALLSCREW

ACTUATING SHAFT

PUNCH KEYHOLE PUNCH

PUNCH GUIDE

M6 SCREW

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) B)

Damaged pins that need replacing. 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

2.4.7.6 Registration Mechanism Replacements Motor (BM5)

This procedure is completed without removing the punch assembly.

1. Access the motor assembly, see Section 2.4.7.1. 2. Remove the motor and gear head (4-off posidrive screws). 3. Replace the motor and check that the pins retract/extend.
service/actuators> set reg_pins on/off

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.

2.4.7.7 Registration Mechanism Checks

1. Check the mechanical condition of the sensor vanes, cam, push-rod and spring
assemblies.

2. Remove the cam, apply a very small amount of light engineering grease to the
operating surface, and refit the cam. registration mechanism:
actuators> set bm5 on actuators> set bm5 off

1. Open Main> Diagnostics and repeatedly check for the smooth operation of the

2. Measure the following parameters with the Engine switched off:

extension of registration pins is 3 to 4 mm retraction of pins is 0.5 to 1.0 mm sub-flush of guides. Adjust, if necessary, to achieve these values by adjust the locknut position on the actuating rod to set the amount pins extend and retract.

2.4.7.8 Centerer Mechanism Replacements Motor (BM3) and Gear Head

This procedure is completed without removing the punch assembly.

1. Access the motor assembly. 2. Remove the motor/gear head bracket (4-off M5 screws) 3. Replace the motor and gear head (with the pinion already fitted on the gear
head shaft).

4. Complete the adjustment check in Section 2.4.7.9.

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)

2.4.7.9 Checking the Centerer Mechanism

See Volume 2 Section 3.4.2.6

1. Switch off power to the platesetter. 2. Access the rear of the punch. 3. Operate the centering arms by hand to ensure that the arms move fully open
(Home position) to fully closed.

4. Check for play between the motor gear and the centering arms. The engagement
of the arm to the gear wheel should allow free movement with the minimum of vertical movement. confirm that the arms home with a smooth mechanical movement.

5. With the centering arms in the fully closed position, re-apply power and

Adjusting the Centerer Mechanism

After replacing the motor or side detect sensors, complete the following:

1. Make sure the scribed lines on each of the arm rails is aligned with the motor/
gear head bracket edges.

2. Make sure there is a vertical clearance of between 0.2 and 0.5 mm between the
arm rail and the motor pinion.

2.4.7.10 Punch Mechanism Replacements Motor (BM4)

This procedure is completed from the service side without removing the punch assembly.

1. Remove the M5 shoulder screw. 2. Remove the 2-off M5 punch bracket screws and remove the bracket (located on
brackets) with the motor, gear head and sensors.

3. Lift out the motor assembly. 4. Refitting is the reverse of removal. Note the orientation of the black/white wires
and check that the motor turns in the correct direction.

5. carry out the punch checks in Section 2.4.7.4.

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

Punch Pins, Dies and Guides

Replacing Billows pins, dies and guides on a Billows field machine is not recommended without further consultation with FFEI Customer Services (UK).

Punch Crop Depth Adjustment

Refer to FFEI Customer Services (UK).

Drag Chain and Wiring Loom Removal

See Figure 2.22. After removing the punch assembly from the machine you can detach the drag chain and wiring loom from the assembly by:

1. Unscrew the drag chain bracket from the beam assembly (2-off posi-screws). 2. Unscrew the drag chain from the centering arm (2-off M3 cap heads). 3. Detach the ground and sensor (continuity) wires. 4. Release the wiring loom P-clips. 5. Replacement is the reverse of removal.

L UXEL P LATESETTER VOLUME 3 (2-47)

DRAG CHAIN

M3 CAPHEADS

POSI-SCREWS (BRACKET)

SENSOR AND GROUND

Figure 2.22 Removing the punch drag chain (new Billows)

2.4.7.11 Registration Mechanism Replacements

See Volume 2 Figure 3.65.

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) B) C)

Remove the registration cam tab (1-off M4). Loosen the centerer rail guides screws (2-off posidrives, top and bottom). 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

service/actuators> set reg_pins on/off

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.

2.4.7.12 Registration Mechanism Checks

1. Manually check the registration pin mechanism by pushing/pulling the
actuating rod. It should be free moving.
>records test >set bm5 on >set bm5 off >ctrl-x (to stop the script)

2. Run the following script:

Alternatively, use the set command to switch the BM5 motor on and off.

3. Check the mechanical condition of the sensor vanes, cam and push-rod
assemblies. surface.

4. Apply a very small amount of light engineering grease to the cam operating

2.4.7.13 Centerer Mechanism Replacements

See Volume 2 Figure 3.60.

Motor (BM3) and Gear Head

This procedure is completed without removing the punch assembly.

1. Access the motor assembly. 2. Loosen the top centerer rail guide to make it easier to insert the motor pinion. 3. Remove the motor/gear head bracket (4-off M5 screws) 4. Replace the motor and gear head (with the pinion already fitted on the gear
head shaft) and secure the top rail guide.

5. Complete the adjustment check in Section 2.4.7.14.

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 midway.

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.

2.4.7.14 Checking the Centerer Mechanism

1. Switch off power to the platesetter. 2. Access the rear of the punch. 3. Operate the centering arms by hand to ensure that the arms move fully open
(Home position) to fully closed.

4. Check for play between the motor gear and the centering arms. The engagement
of the arm to the gear wheel should allow free movement with the minimum of vertical movement. confirm that the arms home with a smooth mechanical movement.

5. With the centering arms in the fully closed position, re-apply power and

2.4.8 Punch, Registration and Centerer (Fuji)

2.4.8.1 Accessing the Assembly
See Figure 2.23 and Figure 2.24. A complete punch assembly (including motors, cables and drag chain) is supplied if the old punch needs to be replaced. The assembly sits on two dowels fitted to the drum casting to allow for accurate location. You do not need to remove the punch motor beforehand. Remove the complete assembly as follows:

1. Move the traverse to the user end. 2. Lower the Buffer to its service position, see Section 2.5.1. 3. Protect the inside of the drum with any heavy-duty material that can take the
dropped weight of the punch.

4. Remove the stretcher panel on the Buffer side of the Engine by removing the 2off screws at the top of the optics base cover and the 4-off M5 Allen bolts holding the panel in place.

5. Remove the output module, see Section 2.4.4.1.

2.4.8.2 Removing the Assembly

CAUTION: If you are replacing a Billows on a Green machine with a Fuji punch, then the output exit guide needs to be replaced and the output raised to avoid fouling the centering arms.

VOLUME 3 (2-50) P LATE H ANDLING S ERVICE P ROCEDURES

S10

CENTERING MOTOR (BM3) REG PIN DC MOTOR

S14 CENTERING ARM (RH)

CENTERING ARM (LH)

S13 S12 PIN/DIE/ CHAD WIPER BS3

A
PUNCH MOTOR (BM4) BS8/9

CENTERING MOTOR S11

REG PIN CAM

NOTE: S12/S13 FITTED TO CENTERING FINGERS ON HIDDEN SIDE REG PIN ACTUATING ARM

REG PIN DC MOTOR (BM5)

UNDERNEATH VIEW ON ARROW A

CENTERING PINION

ACTUATING SHAFT

Figure 2.23 Punch, registration and centerer assemblies

6. Remove the punch motor (optional), see Section 2.4.7.10. 7. Disconnect the following sensor and motor cables to the punch:
A) B) C)

punch motor and sensors (service side) registration motor and sensors (rear of Engine) centering motor and sensors (rear of Engine and both ends) Remove the 8-off M6 bolts set in pairs. Using one person at each end, lift out the assembly. Lift by first raising the user end slightly. Avoid lifting from the drag chain. Check that the two dowels are still in position in the drum.

8. Remove the punch assembly from the drum as follows:

A) B)

C)

9. The complete assembly is serviced by laying it between the two cutouts on the
wooden transit fittings used for the Autofeeder.

L UXEL P LATESETTER VOLUME 3 (2-51)

M6 BOLTS

M6 BOLTS

LOWER BEAM SUPPORT

DRUM CASTING

DOWEL

LOWER BEAM SUPPORT

SERVICE SIDE PLAN VIEW OF DRUM CASTING

Figure 2.24 Removing the punch assembly

2.4.8.3 Complete Punch Replacement

1. If you are fitting a new punch option or complete assembly, check that it has not
been damaged during transit.

2. Make sure the drum surface is fully protected by heavy cardboard. 3. Position the new punch on the dowels (they should fit through the guide holes).
The punch motor will be part of the assembly which makes this operation more awkward. Avoid knocking the carriage flywheel. middle of the punch.

4. Screw in (but do not tighten) the 8-off M6 bolts from the outside towards the 5. Manually check that a large plate can enter and exit the punch correctly without
scratching. Check that the leading edge is picked up by the first output module roller. the aluminium fixing hole threads in the drum are easily damaged.

6. Tighten the M6 bolts from the centre outwards. Do not overtighten the bolts 7. Reconnect all cabling on the service side and the registration/centerer motors.

2.4.8.4 Punch Adjustments and Checks

Visual plate checks are recommended after approximately 35,000 punch operations have been completed. Use the command to check the NVRAM parameter:

VOLUME 3 (2-52) P LATE H ANDLING S ERVICE P ROCEDURES

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.

Visual Plate Punch Check

1. Discuss with the customer any issues or problems that have appeared since the
last service visit.

2. Run a punch job from the RIP. 3. Place the exposed plate on a flat surface and check the following:
A) B)

Punch crops are centred, see Volume 3 Figure 1.8.2.3. Punch crops are the correct depth: standard punch depth at 12 mm, custom at 11 mm crops are equal depth when measured between left and right (specification is 50 microns) crops are cleanly cut without debris in corners or burrs ( Replacing the Punch Pins on page 2-52. plate lead edge to the image start position is inside the specification, see Volume 3 Section 1.8.3.3. 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.

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.

Replacing the Punch Pins

See Figure 2.25 The Fuji punch pins are able to cut at both ends by removing, turning and replacing them during a service visit after checking if there are signs of burring around the punch holes. Use the following procedure to obtain a clean cutting edge:

4 4 4 4 4

L UXEL P LATESETTER VOLUME 3 (2-53)

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

Figure 2.25 Servicing the punch pins

Removing the Punch Motor

This procedure is completed from the service side without removing the complete punch assembly.

VOLUME 3 (2-54) P LATE H ANDLING S ERVICE P ROCEDURES

See Figure 2.26.

1. Disconnect the inline cables to the motor and sensors (BS8 and BS9). 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 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.

BS8 (ON)

PUNCH MOTOR SUPPORT PLATE

MOTOR/GEAR (BM4)

BS9 (OFF)

Figure 2.26 Punch bracket and motor

Replacing the Chad Wipers

See Figure 2.27. Chad wipers, made of Beryllium copper, are replaced every six months to avoid the build-up of chad at the punch exit. Use the following procedure:

1. Remove the punch deflector shield. 2. Remove the wiper with its snap rivet.

L UXEL P LATESETTER VOLUME 3 (2-55)

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.

SNAP RIVET

CHAD WIPER

PUNCH DIE

6 mm CUT CUT CHAD WIPER WIPER MOUNTING BRACKET

DS (ROUND) WIPER TRIM

CHAD DEFLECTOR SHIELD

Figure 2.27 Removing the chad wiper

2.4.9 Swing Roller Module (SRM)

NOTE: Removal is a two-man operation. You do not need to remove the complete module to service the motor and sensors.

2.4.9.1 Swing Roller Module Replacements

See Figure 2.28 and Volume 2 Figure 3.67. The swing roller module (SRM) is located on the drum casting.

1. Move the traverse carriage to its extenders.

VOLUME 3 (2-56) P LATE H ANDLING S ERVICE P ROCEDURES

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 2off 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

REGISTRATION MODULE

DRUM CASTING

BACK STAY

Figure 2.28 Removing the swing roller module

8. Replacement is the reverse of removal. 9. Carry out a plate check described below.

2.4.9.2 Swing Roller Module Checks

Correct operation of the module depends on the height of the media, see Volume 2 Section 2.3.1.4 (large plates) and Volume 2 Section 2.3.1.5 (small plates).

1. Load a plate into the drum as an expose job and check that the spring rollers

push the plate into the drum at the correct sequence for large and small plates.

L UXEL P LATESETTER VOLUME 3 (2-57)

2. Make sure the critical timing sequence operates where the spring rollers contact
a small plate as the plate contacts the registration pins.

2.4.10 Registration Module

2.4.10.1 Registration Module Replacement
NOTE: This module is never removed from an installed system. It is factory-fitted to an exact specification and should not need to be serviced in the field unless the motor or sensors require replacing.

To access the module:

1. Lower the Buffer to its service position, see Section 2.5.1. 2. Remove the stretcher panel on the Buffer side of the Engine by removing the 2off screws at the top of the optics base cover and the 4-off M5 Allen bolts holding the panel in place.

3. Remove the output module and guide plate, see Section 2.4.4.1.

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.

2.5 Buffer Servicing

The Buffer is fitted on all B1 variants except for the B1 Manual machine. Note that the removal and replacement procedure are similar for the fully- and semiautomatic systems. Later Buffer modules are without a sliding labyrinth but have a removable upper cover, allowing improved access to assemblies.

2.5.1 Lowering the Buffer

See Figure 2.29. Lowering the Buffer to its service position (in a vertical position attached to the Processor) allows access to the Buffer assemblies and rear Engine assemblies.

1. Remove the Buffer interlocked top cover and disconnect the three cable
connections to the Engine, see Figure 3.73.

VOLUME 3 (2-58) P LATE H ANDLING S ERVICE P ROCEDURES

NOTE: new Buffers do not have a labyrinth.

PROCESSOR

ENTRY

SHOULDER SCREW FIXING

LOWER BUFFER a) LOWER BUFFER FROM ENGINE

SERVICE SIDE TOP VIEW OF BUFFER WITHOUT SKINS

ENGINE ENTRY

SLIDE ADJUSTER

SLIDE LABYRINTH *

BUFFER FIXING FIXING HEIGHT ADJUSTER RAIL SCREW (1) SCREW (2) ADJUSTER LABYRINTH

b) DISCONNECT BUFFER FROM ENGINE

SERVICE SIDE * LABYRINTH NOT FITTED ON LATER MACHINES

Figure 2.29 Lowering the Buffer (old)

L UXEL P LATESETTER VOLUME 3 (2-59)

PROCESSOR

ENTRY

SHOULDER SCREW FIXING BUFFER

RAISE

a) CONNECT BUFFER TO PROCESSOR

SERVICE SIDE TOP VIEW OF BUFFER WITHOUT SKINS

ENGINE ENTRY

STRETCHER BAR

SLIDE ADJUSTER BUFFER ADJUSTER FIXING SCREW (1) FIXING SCREW (2) SERVICE SIDE

b) RAISE BUFFER TO ENGINE c) SLIDE ADJUSTER ACROSS TO ENGINE

Figure 2.30 Lowering the Buffer (New)

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

2.5.2 Accessing the Buffer Assemblies

See Figure 2.31.
I/F CONNECTORS SERVICE SIDE DRIVE BELTS/ROLLE SENSORS MOTOR

USER SIDE

Figure 2.31 Accessing Buffer assemblies

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.

2.5.2.1 Removing the Upper Cover (Skin)

See Figure 2.32. Removing the upper cover (New Buffers only) gives better access to the motor and gear mechanisms.

1. Remove the top interlocked cover. 2. Detach the three cable connectors from the Engine interface, see Volume 2
Figure 3.73.

3. Remove the 4-off screws holding the upper cover to the frame and lift off the
cover (two-man lift).

L UXEL P LATESETTER VOLUME 3 (2-61)

SERVICE SIDE

CONNECTOR I/F EB BUFFER ENTRY ON ENGINE

Figure 2.32 Buffer-to-Engine interconnections (new)

2.5.3 Motor, Gear and Sensors

See Volume 2 Section 3.1.5 on plate handling.

2.5.3.1 Motor Replacement

1. Open the Buffer cover. 2. Disconnect the three interface cables to the Engine, see Volume 2 Figure 3.73. 3. Remove the 4-off M3 screws holding the motor/gearbox to the chassis, see
Volume 2 Figure 3.69.

4. Unclip the cable back to the BUFF_M7 connector. 5. Remove the motor and drive gear as a single assembly. 6. Fit the replacement motor and drive gear as a single assembly. Ensure that the
grubscrews (2-off M1.5) securing the drive gear to the motor spindle are at a torque greater than 14 kg/cm to avoid slippage.

7. Restore the Buffer assembly to its operating position and reconnect the cables. 8. Check the motor operation by feeding a plate to the Processor.

2.5.3.2 Gear Replacement

See Volume 2 Figure 3.69.

1. Open the Buffer cover. 2. Lower the Buffer to its service position, see Section 2.5.1. 3. Loosen the roller bearing retaining clips. 4. Roller gears are removed by extracting their circlips. 5. Drive gears are removed by taking out the M3 cap head screws. 6. Replace the defective gear wheel and refit the M3 cap head screw or circlip, as
necessary.

VOLUME 3 (2-62) P LATE H ANDLING S ERVICE P ROCEDURES

7. Check the operation of the drive by feeding a plate into the Buffer.

2.5.4 Drive Belts and Rollers

2.5.4.1 Drive Belt Replacement
See Volume 2 Figure 3.69.

1. Open the Buffer cover. 2. Lower the Buffer to its service position, see Section 2.5.1. 3. Remove the broken belt and move the working belts to the service side to leave
space where the new belt will be fitted.

4. Loosen the two bearing retainer clips on each roller on the user side. 5. Lift out each roller and fit the replacement belt. 6. Refit the rollers back into their bearing slots. 7. Remove the 2-off M4 screws holding the plate ramp to the side plate and fit the
replacement belt.

8. Adjust the belts to their correct positions on the rollers. 9. Refit the bearing retainer clips. 10. Check that the rollers operate by feeding a plate through the Buffer.

2.5.4.2 Roller Replacement

See Volume 2 Figure 3.69.
NOTE: Replacement rollers have their bearings already fitted.

1. Open the Buffer cover. 2. If necessary, lower the Buffer to its service position, see Section 2.5.1. 3. Release the bearing retainer clips (M3 Allen) at each end of the roller. 4. Slide out the roller from the drive belts. 5. Fit the replacement roller by sliding it through the belts and into its chassis
mounts.

6. Refit the retainer clips and secure. 7. Re-position the drive belt to the drive wheels. 8. Check the operation of the assembly by feeding a plate into the Processor.

2.5.5 Buffer Alignment Check

After returning the Buffer assembly to its vertical position, check that the height of the first Buffer roller is aligned correctly to the Engine output module guide plate.

Volume-Chapt er

TRAVERSE SCAN SERVICE PROCEDURES

This chapter describes how to replace and set up assemblies on the traverse carriage.

3.1 Starting Scan System Replacements

NOTE: Ensure that the platesetter is powered off at the mains outlet but is still connected to maintain Earth/Ground continuity if there is a risk of static damage to the Traverse PCB. All screw fixings must be replaced with their captive washers (spring and flat), if they are initially fitted. Make sure all cables are properly clamped and tie-wrapped with adequate slack for removing connectors. Check that they are not trapped or mechanically pinched.

3.2 Accessing Traverse Scan Modules

The traverse carriage assemblies are accessed from the service end as follows:

4 4 4

Starting Scan System Replacements ....................................................................... 3-1 Accessing Traverse Scan Modules .......................................................................... 3-1 Replacing Traverse Assemblies ............................................................................... 3-4

1. Shutdown the machine and remove mains input power from the mains
distribution outlet.

2. Open and lift off the service side cover on the Engine. 3. Release the posidrive screw holding the mixer fan bracket, swing the bracket to
one side and remove the drum end cap. procedure, see Figure 3.1.

4. The carriage is positioned at the service (home) end ready for a service

VOLUME 3 (3-2) TRAVERSE SCAN S ERVICE P ROCEDURES

TRAVERSE MOTOR

TRAVERSE BEAM

FLYWHEEL TRAVERSE CARRIAGE

READHEAD DRIVE RAIL EDGE DETECT (LASER/PCB) SPINNER BAFFLE (FIXED)

TRAVERSE PCB

SERVICE SIDE

NOTE: END CAP REMOVED

Figure 3.1 Accessing traverse assemblies - service end view

The traverse mechanisms are manufactured and assembled to a high level of precision to ensure correct exposure registration over the long term. While replacing a traverse part there is always a risk of contamination or damage to important mechanisms. Service engineers need to handle traverse assemblies carefully and gently, while making sure that the carriage and rails are kept clean.
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.

3.2.1 Traverse Carriage Access

See Figure 3.2. Depending on the assembly to be serviced, you can either:

1. Move the carriage to the end of the extenders to replace the following items
while the carriage is located on the extenders:
A) B) C) D) E)

Fixed (PCB) Baffle: see Section 3.3.1. Traverse PCB: see Section 3.3.2. Drive Rail Wiper: see Section 3.3.4. Umbilical Cable: see Section 3.3.5. Spinner: see Section 3.3.6.

L UXEL P LATESETTER VOLUME 3 (3-3)

F) G) H)

Ball Cage: see Section 3.3.7. Readhead: see Section 3.3.8. Edge Detect PCB and laser: see Section 3.3.9.

2. Remove the complete carriage from the service extenders and position it on a
suitable work surface to replace the Traverse Motor, see Section 3.3.3.

BEAM

UMBILICAL TRAY

SERVICE EXTENSION (V-GROOVE)

END STOP DRIVE RAIL SERVICE EXTENSION (FLAT)

Figure 3.2 End of rail and extenders

Moving the Carriage to the Service Extenders

Use the following method to move the carriage onto service extenders:

1. Secure the push bar in its Home position. 2. Follow the steps in Section 3.2 to access the carriage. 3. Pull the carriage by hand along the rail towards the service end. 4. Release the push bar motor cable attached to the end stop (P-clip) and secure it
out of the way.

5. Remove the 2-off M6 Allen caphead screws holding the end stop underneath the
beam and remove the stop bracket.

6. Fit the two extenders (V-groove and flat) to the end of the rail. (The extenders
are normally stored inside the Engine). Use the screw fixings shown in Figure 3.2.

VOLUME 3 (3-4) TRAVERSE SCAN S ERVICE P ROCEDURES

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. Section 3.3.5.

2. Release the umbilical cable from the Traverse PCB and its support bracket, see
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.

3.3 Replacing Traverse Assemblies

3.3.1 Baffle Assemblies
See Figure 3.3. This procedure is completed from the user end and while the carriage is on the extenders.

1. Push the carriage to the user side to access the removable baffle.

L UXEL P LATESETTER VOLUME 3 (3-5)

a) REMOVEABLE BAFFLE

FINGER-TIGHT SCREW (2-OFF)

REMOVEABLE BAFFLE USER SIDE

b) FIXED BAFFLE

SERVICE SIDE

FIXED BAFFLE M5 SCREW (4-OFF)

Figure 3.3 Removing the baffles (removable and fixed)

VOLUME 3 (3-6) TRAVERSE SCAN S ERVICE P ROCEDURES

2. Remove the baffle using the two finger-tight screw fixings. 3. Push the carriage back to the service end and move it onto the extenders, see
Section 3.2.1.

4. Remove the Traverse PCB, see Section 3.3.2. 5. Remove the PCB support bracket by removing its 6-off M4 caphead screws.
Reposition the bracket to one side. brackets.

6. Remove the 4-off M5 screws holding the fixed baffle to the near and front 7. Replacement is the reverse of the removal procedure.

3.3.2 Traverse PCB

CAUTION: When touching or handling the PCB, make sure all antistatic precautions are followed.

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.
test/registry> update_registry system

7. Update the machine system registry file: 8. Expose and test a plate to confirm correct operation.

3.3.3 Traverse Motor

See Figure 3.4. For this procedure you need to remove the carriage from its extenders, see Section 3.2.1, and place it on a work surface.
CAUTION: Make sure the motor shaft is not damaged.

1. Disconnect the motor cable (PL1) from the Traverse PCB. 2. Release the P-clip holding the readhead and motor cables. 3. Detach the flywheel from the motor assembly by removing the 2-off M2.5
caphead screws from the clamp inside and pulling away the wheel. by removing the 3-off screws holding the assembly to the casting.

4. Remove the motor and support casting as a single field replaceable unit (FRU)

L UXEL P LATESETTER VOLUME 3 (3-7)

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

NOTE: THE TRAVERSE MOTOR/SUPPORT CASTING IS REPLACED AS A COMPLETE FRU

FLYWHEEL CLAMP

Figure 3.4 Flywheel and motor - exploded view

3.3.4 Drive Rail Wiper

See Figure 3.5. The wiper forms a housing over the motor shaft and is detached from the motor support casting while the carriage is on the extenders.

1. Move the carriage onto the extenders, see Section 3.2.1. 2. The wiper is fixed by 2-off M4 caphead screws. Loosen (but do not remove) the
screws and lift out the wiper assembly.

3. Clean the wiper felt. Replace the wiper if the felt is worn or damaged. 4. Replacement is the reverse of the removal procedure:
A) B)

clip the wiper to the Allen screws while pushing on the wiper with a finger, tighten the two screws.

VOLUME 3 (3-8) TRAVERSE SCAN S ERVICE P ROCEDURES

FLYWHEEL

SHAFT

WIPER

MOTOR SUPPORT CASTING

Figure 3.5 Accessing the drive rail wiper

3.3.5 Umbilical Cable

See Figure 3.6. This cable can be replaced while the carriage is located on extenders.

1. Disconnect the cable end from SK2 on FHMB (4) by pressing down on the
connector clip with the thumb and pulling out the cable.

2. Remove the cable clamp (M4 screws) holding the cable to the tray. 3. Working from the top, gently remove the cable from the bracket by loosening it
from the button clips.

4. Disconnect the cable end from PL10 on Traverse PCB. 5. Replacement is the reverse of the removal procedure. replace the cable by
working back from the PCB and fastening under the button clips. Make sure the cable is squarely located under the two clamps. runs squarely in the tray. Make sure the traverse initialises correctly on power up.

6. Check that the carriage moves up and down the drum correctly and the cable

L UXEL P LATESETTER VOLUME 3 (3-9)

BUTTON CLIP TO FHMB (4)

PCB SUPPORT BRACKET

UMBILICAL CABLE

TRAVERSE PCB

Figure 3.6 Fitting the umbilical cable

3.3.6 Spinner
CAUTION: Read the spinner disposal notices in Volume 1 Section 3.2.18 before starting this procedure.

See Figure 3.7. This assembly can be removed while the carriage is located on service extenders. To obtain the exact location of the replaced spinner on the casting, follow this replacement procedure carefully. Not completing the procedure correctly could result in scan misalignment.

1. Detach the two connectors (PL4 and PL5) from the Traverse PCB to the spinner. 2. Detach the umbilical cable from the PCB and the first clip on the bracket, and
move to one side.

VOLUME 3 (3-10) TRAVERSE S CAN S ERVICE P ROCEDURES

CARRIAGE CASTING

DOWELS

PADS (4-OFF)

1 LOCATE ON THE
FOUR PADS

2 ROTATE TO

ENGAGE LUG VIEW ON ARROW A

LUG

LUG

SPINNER

3 SCREW SPINNER CLAMPS

INTO POSITION SPINNER CLAMP

A
CLAMP DOWEL SPINNER

Figure 3.7 Re-fitting the 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) B)

Insert the spinner between the clamps so that the lug is top left of centre (1). Rotate the spinner clockwise to engage the lug behind and left of the dowel pins on the casting (2). 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).

C)

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) B) C) D)

Focus and Beam Deflection Absolute Phase (see Volume 3 Section 4.4). Image Form Adjustment (see Volume 3 Section 1.8.1.1). Image base offset (see Volume 3 Section 1.8) for the type of machine. Traverse centre position (see Volume 3 Section 1.8.2.5) or check edge detect sensor offset for the type of machine.

3.3.7 Ball Cage Assembly

CAUTION: This assembly is very accurately assembled. Always make sure that it is supported at each end and is not flexed.

9. Place the carriage on the extenders.

CARRIAGE RAIL

BALL CAGE

TRAVERSE RAIL

Figure 3.8 Replacing the ball cage

10. Push the ball cage to the user end. 11. Lift out the ball cage strip and replace, making sure that the cage is fitted as
shown in Figure 3.8 with the vertical strip uppermost.

12. Setup the ball cage and carriage alignment, see Volume 3 Section 1.7.2.

3.3.8 Readhead
CAUTION: When touching or handling the readhead, make sure all antistatic precautions are followed.

See Figure 3.9. The following item is required: Plastic feeler (Renishaw part no. M-9517-0122) supplied with the readhead part

VOLUME 3 (3-12) TRAVERSE S CAN S ERVICE P ROCEDURES

or as a service tool. Do not use any other type of feeler. Follow the procedure below:

1. Place the carriage on the extenders, see Section 3.2.1. 2. Release the P-clip holding the readhead and motor cables and disconnect the
cable from the Traverse PCB (PL2).

3. Remove the 2-off M4 screws holding the readhead bracket to the motor support
casting and remove the readhead from the bracket.

4. Replace the new readhead onto the bracket and refit the bracket. Make sure that
the bracket is fitted to the casting in its uppermost slot position to give maximum clearance between the head and the scale.

5. Do not tighten the two screws. 6. Return the carriage to the drive rail and move it to the user end. 7. Insert the feeler between the scale and the readhead, then gently press the head
down to give a sliding fit.

8. Tighten each screw in turn, a little at a time, to avoid moving the readhead.
Check again for a sliding fit with the feeler.

9. Refit the cable in the P-clip and reconnect the readhead cable to the Traverse
PCB. Ensure the readhead cable is not bent at an acute angle.

10. Power up the machine. 11. Check that the readhead LED is green over the full length of travel. (The LED
should be visible along the drum from the user end). If not, repeat Steps 7.to 10. until this condition is reached.
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 SUPPORT BRACKET

TRAVERSE MOTOR SUPPORT

FLYWHEEL

READHEAD DRIVE RAIL

MOTOR

INSERT FEELER

LINEAR SCALE

Figure 3.9 Fitting the readhead

3.3.9 Edge Detect PCB and Laser Diode

3.3.9.1 Check Edge Detect Function
Check that the plate edge detect is able to operate as follows:

1. Reboot the Engine. 2. Enter the command:

main> diagnostics/service/traverse> halt traverse>medirq

Check that the Edge Detect PCB laser beam is ON.

3. Load a plate into the drum and move the traverse by hand so that the edge
detect beam moves across the plate edge.

4. Check that the LED on the Edge Detect PCB is OFF when the beam is on the
plate and ON when the beam is on the drum.

5. Press Ctrl-c to exit medirq.

VOLUME 3 (3-14) TRAVERSE S CAN S ERVICE P ROCEDURES

3.3.9.2 Replacing the Edge Detect PCB

See Figure 3.10.

1. Move the traverse onto the service extenders. 2. Disconnect the PCB connectors. 3. From the service end, remove the PCB bracket. 4. Remove and replace the PCB. 5. Align the PCB so that its mounting screw is central in the PCB bracket slot. 6. Switch on the machine and reset the reset the voltage gain using the procedure
in Section 3.3.9.4 (steps 7 to 19).

7. Carry out the edge detect check in Section 3.3.9.1.

REAR BRACKET

FRONT BRACKET

LASER BRACKET

LASER

LENS

PCB

PCB BRACKET

TRAVERSE BAFFLE

Figure 3.10 Edge Detect PCB and laser assemblies

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. 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>

D)

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.

3.3.9.3 Replacing the Laser Diode

See Figure 3.10.

1. Detach the removeable baffle at the MMI end and move the traverse to the
service end.

2. Slide the traverse onto its service extenders. 3. Disconnect the cable from the back of the laser, detach the laser bracket and
remove the old laser.
A)

4. Fit the new laser to the bracket as follows:

Screw the laser (without the lens) to the bracket so that the connector is at the top right-hand corner (looking from the back). Insert the spring washer. Screw the lens to the laser until it is securely held by the spring washer, and then slowly turn it back to its fixed position shown in Figure 3.11:
LENS LASER BRACKET

B) C)

WASHER

Figure 3.11 Laser lens fixing position

VOLUME 3 (3-16) TRAVERSE S CAN S ERVICE P ROCEDURES

NOTE: If the lens window has been handled or looks marked then clean with cotton buds and IPA.

5. Refit the bracket and laser. 6. Follow the setup procedure in Section 3.3.9.4.

3.3.9.4 Edge Detect Setup Procedure

See Figure 3.10.
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

Figure 3.12 Positioning the laser beam

L UXEL P LATESETTER VOLUME 3 (3-17)

ALIGNMENT TOOL BETWEEN GROOVES

TURN LENS

(A)
BEAM IN OFFSET POSITION BEAM IN VERTICAL POSITION

(B)

Figure 3.13 Aligning the laser beam

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.
traverse/datum

7. Move the traverse to the datum point on the other side of the machine: 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

15. Move the carriage until the spot is on the drum. 16. Make sure the DVM reading does not change by more than 0.1 V when working
in darkened conditions. Consult FFEI Customer Support if there is still a problem.

17. Check that the voltage is greater than 2.6 V. If not, then tilt the PCB up a little so
that the right-hand screw is slightly higher than the centre position of the adjustment slot.

18. Move the carriage back and forward over the plate edge. The LED should be 19. Remove the plate. Set the following commands:
>verbose on >medirq

OFF when the laser spot is on the plate, and ON when the spot is on the drum.

20. Move the carriage the full length of the drum making sure the LED stays lit
without flickering. Check that diagnostics error messages show that the laser has not tripped (that is, changed state from drum to plate) during the entire travel to the other end. The number of detect trips are shown as:
edge detect IRQ count: <trip numbers>

21. Complete the check in Section 3.3.9.2 (Step 8). The image should be 1 mm
25 microns from the plate edge. Adjust the NVRAM parameter, microns. Increase the value to push the image further onto the plate.

EDGE_SENSOR_OFFSET, to start the image correctly. A typical value is 3,500

Volume-Chapt er

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.

4.1 Starting Optics Module Replacements

CAUTION: Fixings in the optics base are marked with red paint are NOT disturbed to avoid critical optical components becoming misaligned. 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.

4 4 4 4 4 4 4

Starting Optics Module Replacements ........................................................... Page 4-1 Optics Replacement Setups ............................................................................ Page 4-3 Optics Base Replacements ........................................................................... Page 4-15 Exposing Test Strips ...................................................................................... Page 4-31 Check Raster Quality ..................................................................................... Page 4-50 Calibrate Exposure Level............................................................................... Page 4-51 B1 and B2 Image Form Adjustments ............................................................ Page 4-54

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 recommended service procedures.

VOLUME 3 (4-2) O PTICS SERVICE PROCEDURES

After replacing an optics base module you will need to run the setup and diagnostic procedures shown in Table 4.1.

4.1.1 Accessing Expose Modules

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.

Access the optics modules as follows: Optics base: remove the appropriate enclosure cover to access a laser diode, VBOMB, an optics module or the EODHV devices, see Figure 4.1. Spinner: to access the traverse carriage assemblies, open the engine service door and remove the drum end cap. The carriage can be removed after fitting extension rails. Periscope: to access the periscope assemblies (M1, M2 and LPD), open the engine user door.

USER SIDE

SERVICE SIDE

VBOMB

LASER MODULES (M4, 6-OFF)

OPTICS MODULES (M4, 8-OFF)

EODHV (M4, 2-OFF) AUTOMATIC SHOWN

Figure 4.1 Accessing the optics modules enclosure

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)

4.2 Optics Replacement Setups

After replacing an optics module you will need to carry out one of the setup/ test procedure(s) listed in Table 4.1 and the sections below.
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.

Table 4.1 Optics replacement setups chart

Cleaning FPD, LPD,L6)

Modules:

Aperture Assys

Laser (1-Laser)

Laser (2-Laser)

EODHV TX X/Y

Focus Assys

EODD PCB

LPD Assys

ND Assys

EOD X/Y

Spinner

VBOMB

EODHV

POD

Setups and Tests:

Find LPD position (Section 4.2.1)

Clear laser aging stats (Section 4.2.3) Set up laser current limit (Section 4.2.4) Check power balance (Section 4.2.5) Set laser extinction (Section 4.2.6) Reset beam coincidence (Section 4.2.7) Run Beam_co (Section 4.2.8) Setup and locate FPD (Section 4.2.9) Setup ND characterisation (Section 4.2.10) Reset the spinner contamination check (Section 4.2.11)

aa aa

aaaa

aaaa a a a

aaa

aa aa aa a aa aa aa

Update laser parameters (Section 4.2.2)

FPD

VOLUME 3 (4-4) O PTICS SERVICE PROCEDURES

Table 4.1 Optics replacement setups chart (Continued)

Cleaning FPD, LPD,L6)

Modules:

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

Setups and Tests:

Exposure calibration (Section 4.2.12) Auto focus (Section 4.2.13) Auto ND wedge (Section 4.2.14) Auto threshold wedge (Section 4.2.15) Auto coincidence Y & X (Section 4.2.16) Auto deflection absolute phase for confidence (Section 4.2.17) Auto deflection absolute phase setup (Section 4.2.17)

Image base offset (Section 4.2.21) Edge sensor offset/trav centre position (Section 4.2.22)

aaaaaaaaaaaa

aa

Image check (Section 4.2.23)

aa

aaaa

Expose calibration (Section 4.2.20)

a a a a

aaa aa

Image form adjustment (Section 4.2.19)

aaa

aa

Auto deflection amplitude Y/X (Section 4.2.18)

aaa a aaa aa a a a a a a aaa aaaaaaaaaaaaaaa a

FPD

L UXEL P LATESETTER VOLUME 3 (4-5)

4.2.1 Find LPD Position

Purpose of Setup:
To find the optimum position for reading power from the LPD.

Procedure and Typical Output:

1. Ensure the platesetter is fully booted and the MMI shows the system is in RUN
mode then enter:
edbg 24 diagnostics/service/utils> find_lpd_posn

to obtain:
no input - default lpd end = -294 ****Laser scan params ****Laser scan params laser drive = 1000 , bias = 539 , current limit = 394 Laser Enable server complete. laser 1 shutdown state = FALSE laser drive = 1000 , bias = 584 , current limit = 465 Laser Enable server complete. laser 3 shutdown state = FALSE

VOLUME 3 (4-6) O PTICS SERVICE PROCEDURES

lpd pos = -270, x beam power = 790.250000, y beam power = 732.250000 lpd pos = -271, x beam power = 792.500000, y beam power = 734.500000 lpd pos = -272, x beam power = 794.000000, y beam power = 735.750000 lpd pos = -273, x beam power = 793.750000, y beam power = 738.000000 lpd pos = -274, x beam power = 793.750000, y beam power = 740.500000 lpd pos = -275, x beam power = 794.750000, y beam power = 740.000000 lpd pos = -276, x beam power = 796.500000, y beam power = 744.000000 lpd pos = -277, x beam power = 798.000000, y beam power = 741.000000 lpd pos = -278, x beam power = 800.000000, y beam power = 744.500000 lpd pos = -279, x beam power = 797.250000, y beam power = 740.750000 lpd pos = -280, x beam power = 790.500000, y beam power = 735.750000 lpd pos = -281, x beam power = 788.750000, y beam power = 736.250000 lpd pos = -282, x beam power = 785.000000, y beam power = 728.750000 lpd pos = -283, x beam power = 782.750000, y beam power = 728.000000 lpd pos = -284, x beam power = 784.750000, y beam power = 727.500000 lpd pos = -285, x beam power = 782.750000, y beam power = 726.750000 lpd pos = -286, x beam power = 779.500000, y beam power = 724.250000 lpd pos = -287, x beam power = 670.500000, y beam power = 608.750000 lpd pos = -288, x beam power = 178.000000, y beam power = 154.250000 lpd pos = -289, x beam power = 2.000000, y beam power = 2.000000 lpd pos = -290, x beam power = 3.250000, y beam power = 3.250000 lpd pos = -291, x beam power = 3.000000, y beam power = 3.000000 lpd pos = -292, x beam power = 1.000000, y beam power = 1.000000 lpd pos = -293, x beam power = 0.000000, y beam power = 0.000000 lpd pos = -294, x beam power = 0.000000, y beam power = 0.000000 max pos = -278

2. Enter the command:

ddbg 24
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.

4.2.2 Update Laser Parameters

Purpose of Setup:
Inform machine software of the factory-set original operating conditions for the new laser.

Procedure and Typical Output:

1. Run the command and edit values using the <backspace> key.

L UXEL P LATESETTER VOLUME 3 (4-7)

diagnostics/service/optics/laser> lcpd_params change

to obtain:
Original drive dac x val (dec) Original bias dac x val (dec) 1000 532

Original current limit dac x val (dec) 384 Laser X Wavelength (dec) Original drive dac y val (dec) Original bias dac y val (dec) 405 1000 570

Enter the correct parameters here (using <backspace> to remove the existing values).

Original current limit dac y val (dec) 431 Laser Y Wavelength (dec) 405

CAUTION: Entering incorrect values can cause damage.

Original drive dac x val (dec) Original bias dac x val (dec)

1000 539

3e8 21b 18a

Original current limit dac x val (dec) 394 Laser X Wavelength (dec) Original drive dac y val (dec) Original bias dac y val (dec) 405 1000 584

3e8 248 1d1

Original current limit dac y val (dec) 465 Laser Y Wavelength (dec) 405

Confirm Change UPDATE

4.2.3 Clear Laser Aging Statistics

Purpose of Setup:
To reset the historical laser aging data originally set for the replaced laser.

Procedure and Typical Output:

1. If you have changed X-beam laser then run:
diagnostics/log_utils>clear_laser_x_stat diagnostics/log_utils>laser_x_stat Date Oct 28 16:04:17 2002 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Jan 1 12:00:00 1998 Laser current. 1174 0 0 0 0 0

2. If you have changed Y-beam laser then run:

VOLUME 3 (4-8) O PTICS SERVICE PROCEDURES

diagnostics/log_utils/nvram>clear_laser_y_stat diagnostics/log_utils/nvram>laser_y_stat Date Laser current. Oct 28 16:04:17 2002 1254 Jan 1 12:00:00 1998 0 Jan 1 12:00:00 1998 0 Jan 1 12:00:00 1998 0 Jan 1 12:00:00 1998 0 Jan 1 12:00:00 1998 0
NOTE: These should only show invalid dates and laser power values.

3. Reboot and allow the machine to fully reboot.

4.2.4 Set up Laser Current Limit and Start Aging Log

Purpose of Setup and Typical Output:
The laser current limit protects the laser in the event of external problems. The Aging Log enables the engineer to check how quickly the laser is aging and gives some guidance as to when it may fail.

Procedure:
1. Run the following command:

edbg 40 diagnostics/service/optics/laser>laser_aging Original x current = 1212 read x current = 1260 end of life percentage = 50 End of life current 1818 Original y current = 1157 read y current = 1174 end of life percentage = 50 End of life current 1735 max rate of change = 7 about to do the x actual_rate calc. last x current = 1259 read x current = 1260 actual +ve rate of change 0 about to do the y actual_rate calc. last y current = 1175 read y current = 1174 actual +ve rate of change 0 previous x current limit = 415 new_current_limit x = 415 previous y current limit = 387 new_current_limit y = 387 ddbg 40

See also Volume 2 Section 1.10.4.1 for a description on how to use this command.

4.2.5 Check Power Balance (2-Beam Only)

Purpose of Setup:
To ensure that the 2-beams are at the same power level when they expose a plate. Measured from the LPD, the power reading is equivalent to the power on the plate.

L UXEL P LATESETTER VOLUME 3 (4-9)

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

4.2.6 Set Laser Extinction

Purpose of Setup:
To set the required extinction ratio between the laser drive power and the laser bias power for a required laser.

Procedure and Typical Output:

1. Measure laser extinction values for both lasers as follows:

diagnostics/service/optics/laser>measure_extinction_ratio Laser X extinction ratio = 205.442322 Laser Y extinction ratio = 193.664627

2. The extinction ratios should be between 180 and 220 for both lasers (if fitted). If
they are not then adjust them as follows: to increase the extinction ratio of a laser you need to decrease the bias current to decrease the extinction ratio of a laser you need to increase the bias current.

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

4 4

VOLUME 3 (4-10) O PTICS SERVICE P ROCEDURES

Changing values Working Laser X bias dac value (dec) Working Laser Y bias dac value (dec) 563 526 dec 563 526 hex 233 20e

Remember Incorrect Values can cause damage Working Laser X bias dac value (dec) Working Laser Y bias dac value (dec) Confirm Change Updating Values UPDATE

4.2.7 Reset Beam Coincidence (2-Beam Only)

Purpose of Setup:
To carry out essential recalibrations of the optics.

Procedure and Typical Output:

1. Run the following command (development password is boxer.dev):
development/nvram> snv ORIGINAL_ND_P_POD 0

to obtain:
ORIGINAL_ND_P_POD updated...

min

Parameter |

current

default 0/$00000000

ORIGINAL_ND_P_POD 0/$0000

0/$00000000

4.2.8 Run Beam Coincidence (2-Beam Only)

Purpose of Setup:
To cancel out misalignments within the optics up to the POD. This is added to the Auto Coincidence Y and X set up to provide DC bias on the deflectors when exposing.

Procedure:
1. Run the following:
edbg 19 diagnostics/test/optics> beam_co

2. Check that the beam coincidence utility passes without error messages and
enter:
ddbg 19

L UXEL P LATESETTER VOLUME 3 (4-11)

4.2.9 Set up and Locate FPD

Purpose of Setup:
To inform the machine of the characteristics of the new FPD to ensure accurate exposure calibration.

Procedure and Typical Output:

1. Boot the platesetter and wait until the MMI indicates RUN mode. 2. Enter the following command (development password is boxer.dev):
development/nvram> snv FPD_GAIN <factory value>

to obtain:
FPD_GAIN updated...

Parameter FPD_GAIN

current

default 10.000000

min 1/$0001

<Factory value>

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:
6: High speed detector value = 911 at position 10000 6: High speed detector value = 991 at position 9500 6: High speed detector value = 996 at position 9000 ETC
6: High speed detector value = 930 at position 1500 6: High speed detector value = 494 at position 1000 8: Start of Detector found at 1000 microns 12: High speed detector value = 333 at position 500 ETC

14:Fast Photo Locator - Fast Photo Diode centered at -3750 microns 14:Fast Photo Locator - Fast Photo Diode centered at -3750 microns 14: Fast Photo Locator - NV_TRAV_HIGH_SPEED_POS set to -3750 microns 14:Fast Photo Locator - NV_TRAV_HIGH_SPEED_POS set to -3750 microns

4. Enter:
ddbg 23

VOLUME 3 (4-12) O PTICS SERVICE P ROCEDURES

4.2.10 Set up ND Characterisation

Purpose of Setup:
To inform the machine how power, measured on the LPD, varies with the ND filter position and thereby ensure accurate exposure calibration.

Procedure:
This procedure is now described in Section 4.8 on page 4-63

4.2.11 Reset Spinner Contamination Checks

Purpose of Setup:
Spinner contamination checks tell the operator when to clean the spinner. This routine sets the level of light after the spinner has been cleaned.

Procedure:
1. Clean the spinner. 2. Run the command:
diagnostics/log_utils/nvram> reset_spin_clean_level

4.2.12 Run Exposure Calibration

Purpose of Setup:
To set up the ND filter position for correct power on the plate before setting up the optics.

Procedure:
Follow the procedure in Section 4.6 on page 4-51 below.

4.2.13 Set up Auto Focus

Purpose of Setup:
To set up the correct focus of the laser beam(s) on the plate for best image quality and dot sharpness.

Procedure:
Follow the procedure in Section on page 4-38.

4.2.14 Set up Auto ND Wedge (2-Beam Only)

Purpose of Setup:
To set up the correct level of laser power for exposing the deflection coincidence and absolute phase test plates.

Procedure:
Follow the procedure in Section on page 4-41.

L UXEL P LATESETTER VOLUME 3 (4-13)

4.2.15 Set up Auto Threshold Wedge (2-Beam Only)

Purpose of Setup:
To set up the correct level of laser power for exposing the deflection amplitude test plates (at the plate threshold).

Procedure:
Follow the procedure in Section on page 4-42.

4.2.16 Set up Auto Coincidence Y & X (2-Beam Only)

Purpose of Setup:
To set up the correct value of DC deflection to cancel out misalignments between the POD and the plate. This is added to the beam_co values to provide DC bias on the deflectors when exposing.

Procedure:
Follow the procedures in Section on page 4-42 and Section on page 4-44.

4.2.17 Run Auto Deflection Abs Phase (2-Beam Only)

Purpose of Setup:
To minimise AC deflection in the fast scan direction and to maximise it in the slow direction.

Procedure:
Follow the procedure in `6: Auto Absolute Phase ' on page 4-45.

4.2.18 Run Auto Deflection Amp Y&X (2-Beam Only)

Purpose of Setup:
To set up the AC component of deflection which cancels out the undesirable deflections caused by the spinner.

Procedure:
Follow the procedures in Section on page 4-47 and Section on page 4-49.

4.2.19 Adjust Image Form

Purpose of Setup:
To ensure that the image on the plate is square.

Procedure:
Follow the procedure in Section 4.7 on page 4-54 (for B1 and B2 plates).

VOLUME 3 (4-14) O PTICS SERVICE P ROCEDURES

4.2.20 Run Expose Calibration

Purpose of Setup:
To set up the ND filter position for correct power on the plate before image quality checks and returning the machine to the customer. Note that the setups carried out since the previous calibration may have altered calibrated ND values.

Procedure:
Follow the procedure in Section 4.6 on page 4-51.

4.2.21 Image Base Offset

Purpose of Setup:
To adjust the horizontal position of the image on a plate.

Procedure:
Follow the procedure in Section 1.8.2.6 on page 1-22 and Section 1.8.3.4 on page 1-25.

4.2.22 Edge Sensor Offset/Traverse Centre Position

Purpose of Setup:
To adjust the lateral position of the image on a plate.

Procedure:
Follow the procedure in Section 1.8.3.5 on page 1-26 and Section 1.8.2.5 on page 1-21

4.2.23 Check Image Quality

Purpose of Setup:
To check that the quality of the platesetter output is satisfactory before returning the machine to the customer.

Procedure:
1. Expose a standard Fujifilm Screen and Tint page from the RIP using a Fujifilm
Quality Screen. This page is supplied from the RIP CD during the machine installation. the image.

2. Assess the resulting plates for image quality using the guidelines included in
Refer to Section 4.5 on page 4-50.

L UXEL P LATESETTER VOLUME 3 (4-15)

4.3 Optics Base Replacements

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.

The optics base replaceable assemblies consist of: Sensors - 5 sensors (S1-S5) - see Section 4.3.1. Motors - 4 motors (SM1-SM4) - see Section 4.3.2. Optics modules - laser, EOD and POD. After replacing an optics module inside the optics base or RFI box, check for the appropriate setup and diagnostic procedures shown in Table 4.1. Check for the MODULE name in the lefthand column and run the SETUP ticked for each row.

4.3.1 Optics Base Sensors

The four FRU sensors fitted inside the optics base are: S1: Neutral Density Filter. S2: Focus Limit. S3: Focus Home. S5: Aperture Home. The Laser Power Detector Home (S6) is fitted as part of the LPD.

4.3.1.1 Replace Optics Base Sensors

All sensors in the optics base are opto-slotted and have identical mountings.

1. Disconnect the 3-wire connector to the sensor. 2. Using a 3 mm Allen key, unscrew and remove the Allen screw securing the
sensor to its mounting point.
NOTE: The Allen screw for sensor, S3, is difficult to access and requires a right-angled Allen key.

3. Fitting the new sensor is the reverse of the above.

4.3.1.2 Setup Optics Base Sensors

S2/S3 (Focus)
1. Carry out the setups for the Focus Assys in Table 4.1. 2. Output a typical customer job and check for quality.

S5 (Aperture)
Setups are not required.

S1 (ND Filter)
1. Carry out the setups for the ND Assys in Table 4.1. 2. Output a typical customer job and check for quality.

VOLUME 3 (4-16) O PTICS SERVICE P ROCEDURES

4.3.2 Optics Base Motors

This section describes how to remove the following optics motors: SM1: ND Filter (The motor is replaced as part of the ND Filter assembly). SM2: Focus Adjust. SM3: Aperture Control. SM4: Laser Power Detector.
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.

4.3.2.1 ND Filter Assembly (Including SM1)

NOTE: As the motor gear mesh and filter are set up at the factory, the complete assembly is replaced if the motor fails.

Replace ND Filter Assembly

1. Shutdown the platesetter. 2. Access the optics modules enclosure (fit the PAT and optics service manifold). 3. Disconnect the inline connectors from the motor and sensor. 4. Remove the 3-off M3 screws holding the module to the base, see Figure 4.2. 5. Inspect the new ND filter assembly for dust and clean with a puffer, if
necessary.

6. Fit the new ND filter assembly to the dowel pin and secure using the M3 screws. 7. Reconnect the motor and sensor. 8. Replace the optics module enclosure cover. 9. Switch on the platesetter and setup the filter.

Setup ND Filter Assembly

1. Carry out the setups for the ND Assys shown in Table 4.1. 2. Output a customer job and check for quality.

L UXEL P LATESETTER VOLUME 3 (4-17)

SENSOR (S1) STAY SENSOR BRACKET

ND FILTER

MOTOR BRACKET

FILTER WHEEL

MOTOR (SM1) OLD BASE FIXING LOCATING DOWEL NEW BASE FIXING

Figure 4.2 Replacing the ND filter

4.3.2.2 SM2 (Focus Adjust) Replace SM2

See Figure 4.3.

1. Shutdown the platesetter. 2. Access the optics base interior. 3. Disconnect the inline connector from the motor and sensor. Note the orientation
of the motor connections.

4. Remove the focus adjust cover (3-off screws) secured to the adjust mounting. 5. Remove the 2-off 3 mm caphead screws (3 mm Allen key) holding the motor
bracket to its mounting point.

6. Unclip the spring. 7. The motor shaft is fixed to a gear wheel. Remove the bracket and attached 8. Remove the 4-off crosshead screws securing the motor to the bracket.
motor, taking care to allow the gear wheel to pass through the metalwork hole.

VOLUME 3 (4-18) O PTICS SERVICE P ROCEDURES

9. Remove the gear from the motor shaft. 10. Replacement is the reverse of removal. Make sure the gear is replaced with
grubscrew fixed on the flat surface of the motor shaft.
SPRING

MOTOR SCREWS

MOTOR BRACKET SM2 MOTOR

BRACKET SCREWS

Figure 4.3 Replacing the SM2 motor (Focus Adjust)

Setup SM2
1. Run the setups for the Focus Assys shown in Table 4.1. 2. Output a customer job and check for quality.

4.3.2.3 SM3 (Aperture Control) Replace SM3

See Figure 4.4.

1. Shutdown the platesetter. 2. Access the optics base interior. 3. Remove the aperture control module cover. 4. Disconnect the inline connector from SM3 motor.

L UXEL P LATESETTER VOLUME 3 (4-19)

SPRING BELT MOTOR

S6 SENSOR

BASEPLATE SCREW (4-OFF)

Figure 4.4 Replacing the SM3 motor (Aperture Control)

5. Disconnect the cable to the S6 and S2 sensors. 6. Remove the 4-off M4 Allen caphead screws holding the aperture control module
to the baseplate and remove the module.

7. Note the approximate tension on the drive belt. 8. Remove the single screw (shown at arrow A) holding the drive-belt bracket
located at the opposite end of the motor.

9. Slacken and remove the drive belt from the pulley. 10. Remove the spring from the motor bracket. 11. Remove the 4-off screws securing the bottom of the motor bracket and lift out
the motor.

12. Remove the pulley from the motor. 13. Replacement is the reverse of the removal. Make sure the pulley grubscrew is
against the flat surface of the motor shaft. Tension the drive belt to its previous level.

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

4.3.3 Laser Diode

WARNING: ALWAYS follow the laser warning notices in Volume 1 Section 3.2. 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.

4.3.3.1 Replace the Laser Diode

See Figure 4.5.

1. The diode is delivered with factory-set parameters (written on the module base
plate) that need to be entered from the lcpd-parameters menu, see Volume 2 Section 1.8.3. Note that the NVRAM parameter, ORIGINAL_ND_P_POD, is automatically set back to 0.
CAUTION: Make sure the new data values are entered BEFORE the replaced diode is switched on.

2. Shutdown the platesetter. 3. Access the optics base interior (laser modules). 4. Detach the VBOMB connection. 5. Hold the module in place and remove the 3-off M3 Allen screws. 6. Lift out the module. 7. Replace the new module by locating it against the three dowels and secure to
the baseplate. Secure the screw fixings as follows:
A)

Make sure the module is tight against the dowels and the screws are equally finger-tight. Tighten each screw equally but do not overtighten. Check that the torque setting is approximately 1.4 Nm.

B) C)

8. Re-connect the module cables using the previous cable routing. 9. Refit the module cover.

L UXEL P LATESETTER VOLUME 3 (4-21)

PHOTO DIODE PCB LASER COVER

LASER DIODE DISTRIBUTION PCB PCB

PHOTO DIODE

FIXING SCREWS (3-OFF)

BASEPLATE

DOWELS DOWELS FIXING SCREW FIXING SCREW DOWEL

PLAN VIEW FIXING SCREW PHOTO DIODE PCB

LASER DIODE
PHOTO DIODE PCB DISTRIBUTION PCB

Figure 4.5 Replacing a laser diode module

VOLUME 3 (4-22) O PTICS SERVICE P ROCEDURES

4.3.3.2 Setup the Laser Diode

WARNING: Use the manual shutter on the periscope to prevent beams from entering the drum. 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.

4.3.4 Electro-Optic Deflector (EOD)

Replace EOD Module
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.

Complete the procedure below using the information in Figure 4.6:

1. Shutdown the platesetter. 2. Access the optics base interior. 3. Detach the connector described in Volume 2 Section 5.1.1.16 (note that the red
dots line up when connected).

4. Loosen the 3-off Allen caphead screws. 5. Hold the module in place and start to remove the lower bolt. Lift the module
base slightly to provide enough clearance for removing the bolt, making sure that the EOD V-block is not dislodged from the EOD baseplate. Carefully lift off the module from the baseplate. bolts.Tighten each bolt in turn, making sure their washers are in place against the baseplate.

6. Replace the new EOD by fitting the lower bolt and then the two top

4.3.4.1 Setup the EOD

1. Carry out the setups for EOD X/Y shown in Table 4.1. 2. Output a customer job and check for quality.

L UXEL P LATESETTER VOLUME 3 (4-23)

SHOULDER BOLT (3-OFF) EOD (X)

DOWEL (1)

A
ALLEN CAPHEAD

PLAN VIEW ON ARROW A

EOD (Y)

DO NOT ADJUST

BASEPLATE

FACTORY-SET DO NOT ADJUST

DOWEL (1)

ALLEN CAPHEAD (LOWER)

OPTICS BASEPLATE

Figure 4.6 Positioning the EOD module

4.3.5 Position Detector (POD)

NOTE: The POD detector is pre-aligned at the factory and no more adjustments are required.

VOLUME 3 (4-24) O PTICS SERVICE P ROCEDURES

4.3.5.1 Replace the POD PCB

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.

Complete the procedure below using the information in Figure 4.7.

1. Shutdown the platesetter. 2. Access the optics base interior (optics modules). 3. Disconnect the cable connector from the POD PCB. 4. Remove the 2-off M3 Allen caphead screws. 5. Replace the new PCB by aligning the assembly to the two dowels and refitting
the Allen screws (including captive washers).Insert the screws but do not tighten them.

6. Using your finger, push the base of the module at the furthest corner from the
the two dowels to ensure that the three sides of the POD are hard against the dowels.Tighten the two Allen screws.

7. Reconnect the cable.

POSITION DETECTOR BOARD ASSEMBLY PCB

BASEPLATE

ALLEN SCREW (& CAPTIVE WASHER)

DOWEL

Figure 4.7 Positioning the POD module

4.3.5.2 Setup the POD PCB

1. Carry out the setups for the POD shown in Table 4.1. 2. Output a customer job and check for quality.

L UXEL P LATESETTER VOLUME 3 (4-25)

4.3.6 Electro-Optics Deflector High Voltage (EODHV)

See also Volume 2 Section 5.1.1.16.

4.3.6.1 Replace EODHV PCB

Complete the procedure below using the information in Figure 4.8:

1. Shutdown the platesetter. 2. Access the optics base interior (EODHV). 3. Remove the module cover by slackening the key slot screw. You will need to
unclip and move surrounding cables. connector positions.

4. Disconnect all the cables and wires to the EODHV PCB, noting the push-on 5. Remove the 4-off M4 cap head screws holding the PCB to their pillars. 6. Replacing the PCB is the opposite procedure to its removal.

4.3.6.2 Setup EODHV PCB

1. Carry out the setups for the EODHV shown in Table 4.1. 2. Output a customer job and check for quality.

4.3.6.3 Replace the HV Transformer

1. Remove the EODHV PCB, see above. 2. Disconnect the P-clip to the EOD connector cable and detach the cable by
pulling apart the two locking sections of the connector.

3. Remove the M4 cap head screw holding the transformer to the shim and cover. 4. Replacing a transformer is the opposite procedure to its removal.

4.3.6.4 Setup the EODHV Transformers

1. Carry out the setups for the EODHV X/Y shown in Table 4.1. 2. Output a customer job and check for quality.

VOLUME 3 (4-26) O PTICS SERVICE P ROCEDURES

SPACER

OPTICS COVER

M4 CAP HEAD SCREW (4-OFF) DC - DC CONVERTOR

TRANSFORMERS

TRANSFORMER SHIM

DETACH HERE

TO EOD (X OR Y)

AMPLIFIER M4 CAP HEAD SCREW (2-OFF)

EODHV PCB

HEATSINK

Figure 4.8 Replacing the HV EODD PCB

4.3.7 Laser Power Detector (LPD)

See Figure 4.9. This section describes how to replace the following Laser Power Detector assemblies: LPD PCB Stepper Motor (SM4) Opto-switch sensor (S6) After completing any of the procedures below, use IPA and a lintless cloth to clean the power lens and the ND filter.

L UXEL P LATESETTER VOLUME 3 (4-27)

ND FILTER

LENS AND FILTER MOUNT

DETECTOR PCB

GASKET MASK (BOTH SIDES)

PULLEY SHAFT

TIMING BELT

MOTOR SUPPORT BRACKET

SM4 MOTOR

SECURING SCREW (4-OFF)

Figure 4.9 Replacing LPD motor (SM4)

4.3.7.1 Replace the LPD PCB

See Figure 4.9.
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.

1. Remove the periscope cover (2-off finger-tight screws). 2. Disconnect the cable lead to the LPD PCB and opto-switch sensor.

VOLUME 3 (4-28) O PTICS SERVICE P ROCEDURES

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.

4.3.7.2 Setup the LPD

1. Visually check that the filter and lens assembly moves into the light path so that
the detector on the PCB is approximately in the centre of the light path.

2. Carry out the setups for the LPD Assys shown in Table 4.1. 3. Output a customer job and check for quality.

4.3.7.3 Replace the Motor (SM4)

See Figure 4.9.

1. Remove the periscope cover (2-off finger-tight screws). 2. Release the pulley timing belt. 3. Disconnect the cable lead to the motor. 4. Remove the 3-off M2 caphead screws holding the motor to the support bracket. 5. Replace the motor and refit the belt. The screw fixings are in slots that allow you
to slide the motor to a position where the belt is taut.

6. Tighten the capheads and check if the belt can be twisted (in the middle) by
approximately 90. This indicates the correct tension.

7. Reconnect the cable to the motor.

4.3.7.4 Setup the Motor (SM4)

1. Carry out the setups for the LPD Assys shown in Table 4.1. 2. Output a customer job and check for quality.

4.3.7.5 Replace the Sensor (S6)

See Figure 4.9.

1. Remove the periscope cover (2-off finger-tight screws). 2. Disconnect the cable. 3. Using a 3mm Allen key, remove the Allen screw securing the sensor to its
mounting point.

4. Replacement is the reverse of the removal.

L UXEL P LATESETTER VOLUME 3 (4-29)

SENSOR MOUNTING BRACKET SECURING SCREW

S6 SENSOR

Figure 4.10 Replacing the LPD sensor (S6)

4.3.7.6 Setup the Sensor (S6)

1. Carry out the setups for the LPD Assys shown in Table 4.1. 2. Output a customer job and check for quality.

4.3.8 Optics Motors Board (VBOMB)

4.3.8.1 Replace the VBOMB
Replace the VBOMB as follows:

1. Switch off the engine. 2. Remove the laser modules cover on the optics base, see Figure 4.1. 3. Disconnect all the cables to the PCB, see Volume 2 Section 5.1.6.

VOLUME 3 (4-30) O PTICS SERVICE P ROCEDURES

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.

4.3.8.2 Setup the VBOMB

1. Download the PCB firmware from the RIP PC. Ensure you use the correct
version to match the software versions on the other CAN bus boards. command:

2. Update the registry and confirm that the VBOMB has been changed using the
diagnostics/test/registry> update_registry

1. Carry out the setups for the VBOMB shown in Table 4.1. 2. Output a customer job and check for quality.

4.3.9 Fast Photo Detect (FPD) Sensor

See Volume 2 Section 5.1.5 showing the location of the sensor.

4.3.9.1 Replace the FPD

NOTE: The value of the FPD_GAIN is written on the new FPD PCB. This will be needed for setting up the FPD. Record this value into the Machine Logbook for future reference.

1. Switch off the engine. 2. Fully-Automatic: Remove the PTM service side cover to gain access to the back of
the drum and the FPD.

3. Manual/Semi-Automatic: Remove the plate loader platen to gain access to the

back of the drum and FPD.

4. Disconnect the cable to the FPD. 5. Remove the FPD assembly. 6. Note the FPD gain value on a label attached to the replacement PCB. It should
be typically 10.0 (mA per Watt).

7. Make sure the filter lens is clean using an air duster, if necessary. 8. Fit the new FPD assembly and connect the cable.

4.3.9.2 Setup the FPD

1. Carry out the setups for the FPD shown in Table 4.1. 2. Output a customer job and check for quality.

L UXEL P LATESETTER VOLUME 3 (4-31)

4.4 Exposing Test Strips

4.4.1 Introducing the Test Strip Macros
While in diagnostics (service/optics> optics_mmi) you can generate and expose a range of stepped test strip patterns to verify the alignments and operational settings of the various optical devices. Test strips, generated as macros from a Test Pattern Setup screen (see Figure 4.11), are divided into two types: Automatic: These have test names prefixed with the term `auto'. Each auto test produces and ejects sets of test strips for all resolutions on one or more plates. Note that the default values cannot be overridden. Manual: These produce sets of test strips for one resolution on a single plate using default values that can be overridden. The results of measurements on each test strip pattern determine optimum settings from where you can enter new NVRAM data values.
NOTE: Test strips can be run at any of the 8 resolutions that the Engine supports. However, 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 Ybeams at 48, 72 and 96 resolutions.

VOLUME 3 (4-32) O PTICS SERVICE P ROCEDURES

Auto Abs Phase

This pattern has 2 sets of strips, the first set is used as a diagnostic for deflector system failure, and the other is used to determine absolute phase.

Auto Deflection Amp X/Y

These patterns are used to determine the deflection amplitude of X- and Ybeams at 48, 72 and 96 resolutions.

Focus (Manual)
Allows you to step through all the Focus lens settings for each resolution.

Wedge Density (Manual)

You can step through all the ND wedge settings for each resolution to find a threshold level.

Coincidence Beam X/Y (Manual)

Allows you to apply DC bias to deflectors X or Y to make the beams lie on top of each other with no AC deflection applied.

Deflection Absolute Phase (Manual)

Allows you to alter the phase relationship of the sine and cosine waves relative to the spinner index signal. Line X must write to the plate first, followed by line Y. If the absolute phase is 180 out, then lines X and Y are reversed. If the phase is 90 out, then deflection occurs along the fast direction and not the slow direction.

Amplitude Beam X/Y (Manual)

Allows you to vary the AC deflection voltage for deflectors X and Y to obtain equi-spacing between lines.

4.4.2 Using the Optics_MMI Options

4.4.2.1 Accessing Options
There are four screens available: Test Pattern Setup, Final Values, Extra Options and Machine Setup opened from an engineering terminal window when the following option is entered:
main> diagnostics/service/optics/optics_mmi

4.4.2.2 Navigating Between Options

Use the following keys to select options from any one of the setup screens:
A) Up-

and Down-Arrow keys to move to each item field in a screen in a set order left to right, top to bottom. and Right-Arrow to select from a list of options within a field. or Down to exit from a field.

B) Left

C) Return, Tab, Up

Note that the Final Values screen wraps around for ease of use. All the operator controls for creating and exposing the strips are from the Test Pattern Setup menu. You can select a default screen for a macro and edit the settings for exposing a setup strip.

L UXEL P LATESETTER VOLUME 3 (4-33)

4.4.2.3 Optics Test Pattern Setup Screen

This screen is used for generating sets of test strips, with each strip differing from the previous one by an amount equal to the Step Value entered, see Figure 4.11. From the Test Pattern Setup menu you can access three screens: Extra Options, Final Values and Machine Setups.

Figure 4.11 Optics Test Pattern Setup screen - typical setup

4.4.2.4 Final Values Screen

This screen is used for entering optimum values into NVRAM, see Figure 4.12. On entering the program, the screen values shown are the current values held on NVRAM.

Figure 4.12 Final Values screen - typical setup

When the values have been modified and checked, select:

Y for Save and Exit to write all the values on the screen to NVRAM and

4 4

return to the Test Pattern Setup screen.

Y for Cancel will return you to the Test Pattern Setup screen and leave the

NVRAM parameters unchanged.

VOLUME 3 (4-34) O PTICS SERVICE P ROCEDURES

4.4.2.5 Machine Setup Screen

This screen shows the NVRAM parameters that are normally changed by the service engineer.

Figure 4.13 Machine Setup screen - typical setup

When the values have been modified and checked, select:

Y for Save and Exit to write all the values on the screen to NVRAM and

4.4.2.6 Extra Options Screen

This screen is used for accessing parameters not normally required to be changed in the field, see Figure 4.14. It includes the options: Line Length: the height of the test strip in mm. Image Y Offset: the Y offset from the Base Offset in mm. Strip Gap: distance between test strips in mm. Scan Start X Pos: the default position for the Start Scan. It has no effect on the first expose.

4 4

return to the Test Pattern Setup screen.

Y for Cancel will return you to the Test Pattern Setup screen and leave the

NVRAM parameters unchanged.

Figure 4.14 Extra Options screen - typical setup

L UXEL P LATESETTER VOLUME 3 (4-35)

4.4.2.7 Selecting Options from Test Pattern Setup

Test Macro
This allows you to select the test program from the list above.

Set Defaults
Initially sets all the menu options to their default test values. For manual patterns you can override any of these values from the keyboard; for automatic patterns, the values cannot be overridden.

Scan Start Position

Sets the distance in millimetres from the edge of the plate to the start of the first test strip along the slow scan axis (see Figure 4.15). Note that the first test strip starts on the right and successive strips are shown towards the left.

Strip Width
Sets the width of each test strip in millimetres.

Start Value
The start number for any optical device (stepper motor, etc) which determines the physical position of the device from the home position. The home position is designated as 0, (see Figure 4.15) which shows the ND filter with a Start Value of 60.

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

8 mm STRIP WIDTH

2 mm STEP VALUE

SCAN START POSITION (mm)

Figure 4.15 Test strip - menu set-up terms

VOLUME 3 (4-36) O PTICS SERVICE P ROCEDURES

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 Available, 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 position 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.

4.4.3 Running Test Strips

You can run a set of exposure test plate strips for checking the overall optics performance of the machine and setting new exposure values to NVRAM. These are practical steps that allow you to select a test for each of the main optics modules listed in Table 4.1.

4.4.3.1 Manual and Semi-Automatic Machines (B1 & B2)

For these machines follow the steps below when running test strips:

1. Enter PAUSE mode on the MMI and load a plate. 2. After the plate loads into the drum return to RUN mode. 3. Output the test strip from optics_mmi as shown in the section below and eject
the plate from the MMI.

4.4.3.2 Starting the Tests Running Tests Strips

Use the information in Table 4.2 to run plate exposures for checking Focus, Wedge Density, etc. Each test (1 to 8) results in a plate with a set of strips. Make sure you follow any pre-requirements before starting a test.
Table 4.2 Start test strips (B1 and B2)
Plate Output Tests Test Strip Macro Auto Focus Pre-Requirement Run exposure calibration from the MMI at 50 J setting. Enter 48 and 96 ND values into the ND settings fields of the Final Values table Final Values set for ND Run Power Balance 48, 72 & 96 before starting these tests Run Beam-co from optics_mmi Run Beam-co from optics_mmi Run Beam_co from optics_mmi Run Beam-co from optics_mmi See Page Page 4-38

2 3 4 5 6 7

Auto ND Wedge Density Auto Threshold Wedge Density Auto Coincidence Beam Y Auto Coincidence Beam X Auto Deflection Absolute Phase Auto Deflection Amplitude Beam Y

Page 4-41 Page 4-42 Page 4-42 Page 4-44 Page 4-45 Page 4-47

VOLUME 3 (4-38) O PTICS SERVICE P ROCEDURES

Table 4.2 Start test strips (B1 and B2) (Continued)

Plate Output Tests Test Strip Macro Auto Deflection Amplitude Beam X Pre-Requirement Run Beam-co from optics_mmi See Page Page 4-49

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) B)

B1: 770 mm B2: 600 mm.

50.

1. Calibrate the platesetter at a setting of

screen.

2. Find the ND settings values for 96 and 48 resolutions from the MMI ND Settings 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.
Table 4.3 Auto Focus settings and strips
RUNS TEST STRIPS: AUTO FOCUS MACRO: Focus A Yes 10 8 900 50 9 96 l/mm Vert Focus B N/A N/A 8 900 50 9 96 l/mm Hor Focus C N/A N/A 8 900 50 9 96 l/mm Vert Focus D N/A N/A 8 900 50 9 96 l/mm Hor Focus E N/A N/A 8 900 50 9 48 l/mm Vert

Set Defaults? Scan Start Posn (mm) Strip Width (mm) Start Value Step Value Number of Steps Resolution Pattern Type

L UXEL P LATESETTER VOLUME 3 (4-39)

Table 4.3 Auto Focus settings and strips (Continued)

RUNS TEST STRIPS: AUTO FOCUS MACRO: Focus A 2on2off On Off 1 Beam No Yes Focus B 2on2off On Off 1 Beam No Yes Focus C 2on2off Off On 1 Beam No Yes Focus D 2on2off Off On 1 Beam No Yes Focus E 2on2off Off On 1 Beam No Yes

Lines Beam X Beam Y Traverse Speed Use Threshold? Start Scan

6. Eject and process the plate. 7. Check Strips A to D at 96 Resolution: Using a densitometer, find the lightest
density strip for each focus test strip shown in Figure 4.16. This should be in the range of 1000 to 1200. Check the top and bottom of the plate, and ensure that:
A)

The 2 lightest values, top and bottom, from each block of test strips should be within 1 strip of each other (ie adjacent). Obtain a single average value. The average value of the 4 blocks (A to D), top and bottom, should be within 2 strips of each other.

B)

8. Enter the 96 value into the 1800, 72, 2400, 96, 100 and 144 positions for the plate
thickness used.

9. Check Strip E at 48 resolution: find the lightest strips, top and bottom, and
obtain the average value. thickness used.

10. Enter the 48 resolution value into the 1200 and 48 positions for the plate 11. Save the focus step positions in the Final Values table. 12. Find the focus step positions for each remaining plate thickness by calculating
the offset values from Table 4.4.
:

Table 4.4 Focus positions for plate type thickness

Tested Plate Thickness (mm): Offset for Plate: 0.2 0.24 0.3 Focus Offset Value:

0.15

Subtract 15 Subtract 27 Subtract 45 Add 15 Subtract 12 Subtract 30

0.2

0.15 0.24 0.3

VOLUME 3 (4-40) O PTICS SERVICE P ROCEDURES

Table 4.4 Focus positions for plate type thickness (Continued)

Tested Plate Thickness (mm): Offset for Plate: 0.15 0.2 0.3 Focus Offset Value:

0.24

Add 27 Add 12 Subtract 18 Add 45 Add 30 Add 18

0.3

0.15 0.2 0.24

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) B) C)

0.24 mm = 1218 0.2 mm = 1230 0.15 mm = 1245.

BLOCK OF TEST STRIPS

TOP VALUE

BOTTOM VALUE

BEST AVERAGE FOCUS

Figure 4.16 Selecting best block focus test strip

13. If any of these focus conditions cannot be met then:

A)

Try a different value for ND and check the processor setup.

L UXEL P LATESETTER VOLUME 3 (4-41)

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.

2: Auto ND Wedge Density

These test patterns find the ND wedge positions that give distinct 1 ON 1 OFF vertical line images. These numbers are important since 1 ON 1 OFF vertical lines are used for Coincidence X/Y.
EQUAL LINE AND GAP WIDTHS

DENSITY READING IS ABOUT 50% 1 ON/ 1 OFF

Figure 4.17 Checking the line/gap patterns

1. Output test strips using the settings below. 2. Check for lines of 1 beam width with equal width gaps between them, see
Figure 4.17.

3. Enter these ND setting values into the Final Values table.

Table 4.5 Auto ND Wedge settings and strips
RUNS TEST STRIPS: AUTO ND WEDGE DENSITY Wedge Density Yes 10 8 140 5 11 48 Vert Wedge Density N/A N/A 8 140 5 11 72 Vert Wedge Density N/A N/A 8 120 5 11 96 Vert

Set Defaults? Scan Start Posn (mm) Strip Width (mm) Start Value Step Value Number of Steps Resolution Pattern Type

VOLUME 3 (4-42) O PTICS SERVICE P ROCEDURES

Table 4.5 Auto ND Wedge settings and strips (Continued)

RUNS TEST STRIPS: AUTO ND WEDGE DENSITY Wedge Density 1on1off Off On 1 Beam No Wedge Density 1on1off Off On 1 Beam No Wedge Density 1on1off Off On 1 Beam No

Lines Beam X Beam Y Traverse Speed Use Threshold?

3: Auto Threshold Wedge Density

See Page 4-41

1. Output a plate using the settings below: 2. Select the strips which show black lines on both beams clearly from the top to
bottom of the plate. Enter the values into the 48, 72 and 96 Final Values table for ND Threshold.
Table 4.6 Auto Threshold settings and strips
RUNS TEST STRIPS: AUTO THRESHOLD WEDGE DENSITY: Wedge Density Yes 10 8 90 2 20 48 Black Black Off On 1 Beam No Wedge Density N/A N/A 8 90 2 20 72 Black Black Off On 1 Beam No Wedge Density N/A N/A 8 80 2 20 96 Black Black Off On 1 Beam No

Set Defaults Scan Start Position Strip Width Start Value Step Value Number of Steps Resolution Pattern Type Lines Beam X Beam Y Traverse Use Threshold

4: Auto Coincidence Beams Y

This test is used to make the two beams (at the drum) lie on top of each other at the Y deflection position when AC deflection is not applied. Run beam_co from the Test Pattern Setup menu first to ensure co-incidence on the POD.

L UXEL P LATESETTER VOLUME 3 (4-43)

Since it is difficult to visually check if two beams are on top of each other, a special 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.
PLATE LEADING EDGE (REG PINS) 96 72 48 96 72 48 320 mm (PUNCH) 298 mm (NO PUNCH)

DEFLECTOR POINT (Y)

432 mm

X-BEAM TEST STRIPS

DEFLECTOR POINT (X)

Y-BEAM TEST STRIPS

Figure 4.18 Auto Coincidence check 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):
Table 4.7 Auto Coincidence Beam Y settings and strips
RUNS TEST STRIPS: AUTO COINCIDENCE BEAM Y: Coin Beam Y Yes 10 8 -250 50 11 48 Vert Coin Beam Y N/A N/A 8 -250 50 11 72 Vert Coin Beam Y N/A N/A 8 -250 50 11 96 Vert

Set Defaults? Scan Start Posn (mm) Strip Width (mm) Start Value Step Value Number of Steps Resolution Pattern Type

VOLUME 3 (4-44) O PTICS SERVICE P ROCEDURES

Table 4.7 Auto Coincidence Beam Y settings and strips (Continued)

RUNS TEST STRIPS: AUTO COINCIDENCE BEAM Y: Coin Beam Y 1on3Off * On On 1 Beam No Coin Beam Y 1on3off * On On 1 Beam No Coin Beam Y 1on 3off * On On 1 Beam No

Lines Beam X Beam Y Traverse Speed Use Threshold?

NOTE: indicates a special test pattern producing 1 ON 1 OFF lines. *

2. Check at the Y deflector point for best equal spaced lines. 3. Enter values into the Final Values table.
A)

Enter the 48 resolution value into the 1200 and 48 positions for Y OFF EOD line. Enter the 72 resolution value into the 1800 and 72 positions for Y OFF EOD line. Enter the 96 resolution value into the 2400, 96, 100 and 144 positions for the Y OFF EOD line.

B)

C)

NOTE: indicates a special test pattern producing 1 ON 1 OFF lines. *

5: Auto Coincidence Beam X

1. Run beam_co. 2. Output a set of test strips using the table below:
Table 4.8 Auto Coincidence Beam X settings and strips
RUNS TEST STRIPS: AUTO COINCIDENCE BEAM X: Coin Beam X Yes 10 8 -250 50 11 48 Vert Coin Beam X N/A N/A 8 -250 50 11 72 Vert Coin Beam X N/A N/A 8 -250 50 11 96 Vert

Set Defaults? Scan Start Posn (mm) Strip Width (mm) Start Value Step Value Number of Steps Resolution Pattern Type

L UXEL P LATESETTER VOLUME 3 (4-45)

Table 4.8 Auto Coincidence Beam X settings and strips (Continued)

RUNS TEST STRIPS: AUTO COINCIDENCE BEAM X: Coin Beam X 1on3Off * On On 1 Beam No Coin Beam X 1on3off * On On 1 Beam No Coin Beam X 1on 3off * On On 1 Beam No

Lines Beam X Beam Y Traverse Speed Use Threshold ND?

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. Enter the 72 resolution value into the 1800 and 72 positions for the X OFF EOD line. Enter the 96 resolution value into the 2400, 96, 100 and 144 positions for the X OFF EOD line.

B)

C)

6: Auto Absolute Phase

The first pattern is used to check that all the components in the deflection system are working properly. The second pattern is used to set up Absolute Phase. The items checked are the EODD board sine and cosine wave generation, the EODHV board, the HV transformers and the EODs. For a working deflection system there should be two dark vertical bands down the plate at Deflector Absolute Phase settings of approximately 400 and 1100 (in the first test pattern).

1. Run the test strips using the settings below:

Table 4.9 Auto Absolute Phase settings and strips
RUNS TEST STRIPS: AUTO ABSOLUTE PHASE: Deflection Abs Phase Yes 10 8 0 100 Deflection Abs Phase N/A N/A 8 900 50

Set Defaults? Scan Start Posn (mm) Strip Width (mm) Start Value Step Value

VOLUME 3 (4-46) O PTICS SERVICE P ROCEDURES

Table 4.9 Auto Absolute Phase settings and strips (Continued)

RUNS TEST STRIPS: AUTO ABSOLUTE PHASE: Deflection Abs Phase 15 96 Vert 2on2off On On 2 Beam No Deflection Abs Phase 7 96 Hor 1on3off On On 2 Beam No

Number of Steps Resolution Pattern Type Lines Beam X Beam Y Traverse Speed Use Threshold?

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 LAST STRIP

900

800

700

600

500

400

300

200

100

FIRST STRIP

Figure 4.19 Deflection strips for 1st test pattern

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)

X-DEFLECTION ERROR

Y-DEFLECTION ERROR

L D

L L D D L L D
2 ON/2 OFF L = LIGHT D = DARK 2 ON/2 OFF

Figure 4.20 Fault indications on X- and Y-deflections

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. the lines appear jaggied, see Figure 4.21.
BEST HORIZONTAL LINE

4. Find the best horizontal lines; if the dots are either side of the correct position,

JAGGIED LINE

Figure 4.21 1 ON 3 OFF horizontal line

5. Enter the setting for the best horizontal lines into the Final Values screen for the
Deflection Absolute Phase field.

7: Auto Deflection Amplitude Beam Y

Beam coincidence is run first from the optics_mmi screen to give coincidence on the POD.

1. Output test strips using the settings below:

VOLUME 3 (4-48) O PTICS SERVICE P ROCEDURES

Table 4.10 Auto Deflection Amplitude Beam Y settings and strips

RUNS TEST STRIPS: AUTO DEFLECTION AMPLITUDE: Amp Beam Y Yes 10 8 0.7 0.05 17 48 Black Black On On 2 Beam Yes Amp Beam Y N/A N/A 8 0.7 0.05 17 72 Black Black On On 2 Beam Yes Amp Beam Y N/A N/A 8 0.7 0.05 17 96 Black Black On On 2 Beam Yes

Set Defaults Scan Start Position Strip Width Start Value Step Value Number of Steps Resolution Pattern Type Lines Beam X Beam Y Traverse Use Threshold

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.
PLATE LEADING EDGE (REG PINS) 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. resolutions:
A) B) C)

4. Insert these values into the Y AMP EOD fields of the Final Values table for the
48 into columns 1200 and 48 72 into columns 1800 and 72 96 into columns 2400, 96, 100 and 144.

8: Auto Deflection Amplitude Beam X

1. Output test strips using the settings below:
Table 4.11 Auto Deflection Amplitude Beam X settings and strips
RUNS TEST STRIPS: AUTO DEFLECTION AMPLITUDE: Amp Beam X Yes 10 8 0.7 0.05 17 48 Black Black On On 2 Beam Yes Amp Beam X N/A N/A 8 0.7 0.05 17 72 Black Black On On 2 Beam Yes Amp Beam X N/A N/A 8 0.7 0.05 17 96 Black Black On On 2 Beam Yes

Set Defaults Scan Start Position Strip Width Start Value Step Value Number of Steps Resolution Pattern Type Lines Beam X Beam Y Traverse Use Threshold

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. resolutions:
A) B) C)

4. Insert these values into the X AMP EOD fields of the Final Values table for the
48 into columns 1200 and 48 72 into columns 1800 and 72 96 into columns 2400, 96, 100 and 144.

On a B2 machine, the plate is not high enough to view the patterns at the Xdeflector 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.
PLATE LEADING EDGE (REG PINS) 96 72 48 752 mm (PUNCH) 730 mm (NO PUNCH)

X-BEAM TEST STRIPS

Figure 4.23 Auto Deflection Amplitude test strips (X)

4.5 Check Raster Quality

Raster quality on the plate can deteriorate if there is a problem in the following optics settings:

Processor
This has a large effect if the brush roller pressures, the chemistry or the temperatures are incorrect. Ensure that the processor is in good condition. To check for processor-induced raster, expose the plate then turn it through 90 before

L UXEL P LATESETTER VOLUME 3 (4-51)

processing. Any processor marks will now be in the other direction.

Focus
Poor focus causes a general degradation of the raster. Check that the focus is correctly set.

Two Beam Setup

Errors in the two beam setup causes poor raster which may be worse at different positions in the vertical direction. The parameters most likely to cause raster are Coincidence X and Y and Amplitude X and Y. This is because there is only a small overlap of the beams, and errors in beam position cause white gaps to appear between the lines, so leading to noticeable raster. Errors in the X beam setup are most likely to cause raster close to 750 mm down from the punch, which is where the X deflector works with maximum amplitude. Errors in the Y beam setup are most likely to cause raster close to 320 mm down from the punch. As a useful test to check for two beam raster, complete the following:
1. Switch the engine to single beam. Change the NVRAM parameter 2. Run a test image. 3. Ensure that LASERS_USED is set back to 5 afterwards otherwise the

LASERS_USED from 5 to1 to use the X beam, or to 4 for the Y beam.

machine will run in single beam mode.

4. Reset the Engine then shutdown and restart the RIP.

Traverse
This produces vertical lines which extend from top to bottom of the plate. To avoid raster problems, ensure that the traverse encoder track is clean and that ball cage creep is within specification.

Thermal
Thermal gradients, somewhere in the optics, can produce random dark and light vertical lines which may extend from top to bottom of the image. Alternatively, localised hotspots around the drum may cause lines which do not extend top to bottom. Ensure that the mixer fan is working and airflow is not restricted, as this has a big impact on the raster.

4.6 Calibrate Exposure Level

Exposure calibration sets up a constant exposure level at the drum surface for each resolution. The correct default level is 50 set on the MMI. This corresponds to the following exposure and power levels:
Table 4.12 Laser exposure and power levels
Resolution Exposure Level (J/cm2) Power (mW)

47

50

13.2

VOLUME 3 (4-52) O PTICS SERVICE P ROCEDURES

Table 4.12 Laser exposure and power levels

Resolution Exposure Level (J/cm2) Power (mW)

48 71 72 94 96 100 144

50 50 50 65 65 65 65

13.0 10.6 10.4 11.0 10.8 10.4 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

Figure 4.24 Exposure Calibration screen

2. Press Start Calibration to measure the exposure level at the drum and calculate the
ND settings of the filter wheel for all resolutions.
A)

3. The screen shows a Wait Timer icon during the calculations and then indicates:
Successful calibration: a tick appears on the Exposure Calibration screen. None of the resolutions have failed. 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.

B)

L UXEL P LATESETTER VOLUME 3 (4-53)

Figure 4.25 ND Settings screen

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

4.7 B1 and B2 Image Form Adjustments

These procedures show how to check the geometry of an exposed B1 and B2 image on a plate and adjust for errors. Adjustments are based on the following plate sizes:
A)

B1: 865 mm for the fast scan (vertical) and 865 mm for the slow scan (horizontal) length. B2: 665 mm for the fast scan (vertical) and 665 mm for the slow scan (horizontal) length. the laser system is upgraded from one to two beams. a spinner change a laser diode change any other changes or adjustments that alters beam direction.

B)

An image form adjustment is normally carried out when:

A) B) C) D)

Requirements for running the adjustments are: Grid: output a PI (Tests_C) image with (865 mm x 865 mm size grid for B1) or (665 mm x 665 mm size grid for B2). Alternatively, you can generate a grid from QuarkXpress. Plate: minimum size is:
A) B)

B1: 890 mm (H) x 870 mm (W) x (0.3 or 0.24 mm). B2: 670 mm (H) x 670 mm (W) x (0.2, 0.3 or 0.24 mm).

Microscope: with 20 m resolution graticule. Film comparison ruler: use the method in Section 4.7.1 to create a ruler for determining errors by measuring grid comparisons on the same plate. Error adjustments are completed from the M2 mirror shown in Figure 4.26.

L UXEL P LATESETTER VOLUME 3 (4-55)

M2 SCREW ADJUSTMENT (HORIZONTAL/VERTICAL) POINTER 1/20 TURN CLOCKWISE 1/20 TURN ANTI-CLOCKWISE POINTER

HORIZ. = 20 DIVISIONS

VERT. = 20 DIVISIONS

ADJUSTING SCREW (VERTICAL)

LOCKNUT

M2 MIRROR

ADJUSTING SCREW (HORIZONTAL)

HOUSING

Figure 4.26 M2 mirror adjustment

4.7.1 Creating a Film Comparison Ruler

Create a film comparison ruler as follows:

1. Output a grid film strip from an imagesetter and cut four horizontal strips
approximately 100 mm wide, see Figure 4.27.
A)

B1 Plate: tape the two strips together on both sides to obtain one long 1,223 mm strip. B2 Plate: use Strip 0, which should be longer than 940 mm.

B)

VOLUME 3 (4-56) O PTICS SERVICE P ROCEDURES

STRIP 0 CUT STRIP 1 CUT STRIP 2 CUT STRIP 3 CUT APPROX. 100 mm WIDE STRIP

1130 mm STRIP 1

B1 RULER

STRIP 2 TAPE 1223 mm STRIP 0 B2 RULER

940 mm

Figure 4.27 Cutting/joining the film strips

4.7.2 Determining Horizontal Error

This method uses the film ruler to find horizontal errors.

1. Output a plate with a PI (Test_C) grid and place the plate on a flat table 2. Align a grid cross-point at one end exactly on the corner of the image for
diagonal B and make sure the centre line of the ruler is exactly aligned on the corner at the other end, see Figure 4.28. measuring line X.

3. Tape the ruler to the plate and mark the grid cross point at one end and the grid 4. Using a microscope, measure how much the corner at the other end overlaps the
nearest grid cross point from `X', see Figure 4.28. (Take care when measuring with a microscope - the view is inverted).

5. Repeat steps 2. to 4. for diagonal A. 6. Calculate the difference between A and B diagonals. 7. Complete the correction procedure in Section 4.7.2.1.1 from step 2. onwards.

L UXEL P LATESETTER VOLUME 3 (4-57)

865 mm (B1) 665 mm (B2) IMAGE

MEASURE

865 mm (B1) 665 mm (B2)

B GRID CROSS POINT ON CORNER

FILM COMPARISON RULER

Figure 4.28 Measuring horizontal errors with a film strip ruler

4.7.2.1 Correcting Horizontal Error

Use one of the following two methods to measure horizontal error, which is the difference between the two diagonals (A and B) shown in Figure 4.29.
1. Vernier ruler (1.25 m minimum) to measure the diagonals A and B. This

method is straightforward: measure A and B and subtract the difference to determine the direction and magnitude of the adjustment.

2. Film Comparison Ruler (see Section 4.7.1) and a microscope.

The specification for the image form horizontal check should be less than 50 m difference between A and B.

1. Output a plate with a PI (Test_C) grid and check if there is a difference between
the diagonal measurements.

2. If the difference exceeds the specification, then make an M2 adjustment. 3. Remove the cover around the M2 mirror on the user side.

VOLUME 3 (4-58) O PTICS SERVICE P ROCEDURES

PLATE GRID IMAGE

B 865 mm (B1) 665 mm (B2)

865 mm (B1) 665 mm (B2)

Figure 4.29 Horizontal check

4. If B is greater than A, as in Figure 4.30, then adjust the M2 horizontal screw

clockwise.

PUNCH END GRID IMAGE

PLATE

Figure 4.30 Horizontal check - B greater than A

5. If A is greater than B, as in Figure 4.31, then adjust the M2 horizontal screw anticlockwise.

L UXEL P LATESETTER VOLUME 3 (4-59)

PUNCH END GRID IMAGE

PLATE

Figure 4.31 Horizontal check - A greater than B

6. B1 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) B) C)

One division turn on the horizontal adjuster screw = 50 m correction. Ten divisions turn on the horizontal adjuster screw = 500 m correction. Twenty divisions turn on the horizontal adjuster screw = 1 mm correction. One division turn on the horizontal adjuster screw = 47 m correction. Ten divisions turn on the horizontal adjuster screw = 470 m correction. Twenty divisions turn on the horizontal adjuster screw = 0.94 mm correction.

7. B2 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) B) C)

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.

4.7.3 Determining Vertical Error

This method uses the film ruler to find vertical errors.

1. Output a plate with the PI (Test_C) grid and place the plate on a flat table. 2. Using the ruler, check for bow on the vertical centre line. 3. Place the centre line of the ruler on the centre line of the grid, as shown in
Note the direction of the bow towards or away from the periscope end. Figure 4.32, and measure the bow to obtain value A (for instance, 100 m).

VOLUME 3 (4-60) O PTICS SERVICE P ROCEDURES

PUNCH END GRID IMAGE

PLATE

SERVICE END

MEASURE A (EXAMPLE: 100 m)

PERISCOPE END

FILM COMPARISON RULER

Figure 4.32 Measuring vertical errors with ruler position A

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.
PUNCH END GRID IMAGE PLATE FILM COMPARISON RULER TURNED

SERVICE END

MEASURE B (EXAMPLE: 60 m)

PERISCOPE END

Figure 4.33 Measuring vertical errors with ruler position B

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)

4.7.3.1 Correcting Vertical Error

This measures the amount of vertical line bow from a centre vertical line on a grid image. The specification for vertical line bow should not exceed 20 m on the centre vertical line.

1. Output a plate with a PI (Test_C) grid and find the centre vertical line. 2. Using a horizontal grid line of the B2 ruler, check for bow on the centre vertical
grid line as shown in Figure 4.34.

3. If the bow exceeds the specification, then make an M2 adjustment. 4. Remove the cover around the M2 mirror on the user side.
PUNCH END GRID IMAGE PLATE

SERVICE END

STRAIGHT LINE OF FILM GRID CENTRE LINE (B2 RULER)

VERTICAL LINE BOW

PERISCOPE END

FILM GRID

Figure 4.34 Checking for vertical bow

5. If the vertical bow is away from the periscope end, then adjust the M2 vertical
screw clockwise.

PUNCH END GRID iMAGE

PLATE

SERVICE END

PERISCOPE END

Figure 4.35 Vertical check - away from the periscope

VOLUME 3 (4-62) O PTICS SERVICE P ROCEDURES

6. If the vertical bow is towards the periscope end, then adjust the M2 vertical screw
anti-clockwise.

PUNCH END GRID IMAGE

PLATE

SERVICE END

PERISCOPE END

Figure 4.36 Vertical check - towards the periscope

7. B1 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) B) C)

One division turn on the vertical adjuster screw = 15 m correction. Ten divisions turn on the vertical adjuster screw = 150 m correction. Twenty divisions turn on the vertical adjuster screw = 300 m correction. One division turn on the vertical adjuster screw = 8 m correction. Ten divisions turn on the vertical adjuster screw = 80 m correction. Twenty divisions turn on the vertical adjuster screw = 160 m correction.

8. B2 Plate: Loosen the adjuster locknut and re-adjust as follows (see Figure 4.26):
A) B) C)

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)

4.8 Set up ND Characterisation

1. Set ND_MAX_TRANSMISSION to its maximum possible setting by entering:
main> dev

enter the password:

boxer.dev

and from the r&d_main prompt enter:

r&d_main> nvram nvram> dnv ND_MAX_TRANSMISSION

Parameter ND_MAX_TRANSMISSION

| current | default 202/$000000ca 160/$000000a0

nvram>snv ND_MAX_TRANSMISSION 240 ND_MAX_TRANSMISSION updated... Parameter ND_MAX_TRANSMISSION | 240/$000000f0 current | default 160/$000000a0 |

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

nd pos = 20 , X and Y beam power = 0.000 nd pos = 21 , X and Y beam power = 0.000 nd pos = 22 , X and Y beam power = 0.000 nd pos = 23 , X and Y beam power = 0.000 etc. nd pos = 196 , X and Y beam power = 1462.750 nd pos = 197 , X and Y beam power = 1491.000 nd pos = 198 , X and Y beam power = 1517.250 nd pos = 199 , X and Y beam power = 1527.750 nd pos = 200 , X and Y beam power = 1537.000 nd pos = 201 , X and Y beam power = 1542.250 nd pos = 202 , X and Y beam power = 1547.250 nd pos = 203 , X and Y beam power = 1550.750 nd pos = 204 , X and Y beam power = 1543.500 nd pos = 205 , X and Y beam power = 1548.500 nd pos = 206 , X and Y beam power = 1535.250 nd pos = 207 , X and Y beam power = 1548.000 nd pos = 208 , X and Y beam power = 1523.250 etc nd pos = 216 , X and Y beam power = 1487.500 nd pos = 217 , X and Y beam power = 1495.750 nd pos = 218 , X and Y beam power = 1505.000 nd pos = 219 , X and Y beam power = 1432.750 nd pos = 220 , X and Y beam power = 1273.250 nd pos = 221 , X and Y beam power = 978.750 nd pos = 222 , X and Y beam power = 729.750 nd pos = 223 , X and Y beam power = 841.500 nd pos = 224 , X and Y beam power = 1088.750 nd pos = 225 , X and Y beam power = 1279.250 nd pos = 226 , X and Y beam power = 1529.000 nd pos = 227 , X and Y beam power = 1614.500 nd pos = 228 , X and Y beam power = 1641.750 nd pos = 229 , X and Y beam power = 1644.250 etc nd pos = 239 , X and Y beam power = 1650.250 nd pos = 240 , X and Y beam power = 1650.500 ND char table start index = 0 , start value = 0.000000 ND char table end index = 220 , end value = 1650.500000 TIME:Mon Apr 7 11:35:20 2003 (119781) irq_handlers.c:137 (ERROR) ** ERROR: 3205, *** No Isr for expose completed - level 3!.

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

general/tmpReg.txt general/sysnvram.bin general/nd_char general/media_dbase general/cassettes general/elevator general/jm.dat general/stats.txt general/sysconfig.txt

6543 14451 512 648 1054 24 4530 4672 1209

Apr Apr Apr Apr Apr Apr Apr Apr Apr

7 10:16:00 2003 2 11:10:44 2003 7 11:35:20 2003 2 14:42:26 2003 2 15:34:34 2003 2 13:00:08 2003 2 15:35:32 2003 7 10:16:01 2003 2 11:11:29 2003

5. Check the following:

A)

the file size of general/nd_char is not 0

L UXEL P LATESETTER VOLUME 3 (4-65)

B)

the date and time of general/nd_char is the same as Time: recorded near the end of the nd_char text. the maximum X and Y beam power is at least 800

C)

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 Laser Power (LPD) 1400 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.

7. Set up the working range of the ND filter as follows:

A)

set up in NVRAM the position of ND filter for maximum transmission of light, which is at the end of the working range. Look at the text generated by nd_char. Starting at nd pos = 170, look at the values of X and Y beam power. In the working range they should increase continuously. Look for the first drop in power. In the example above, it is from step 203 (X and Y beam power = 1550.750) to step 204 (X and Y beam power = 1543.500). In the example above, the end of the working range is therefore 203. You may find a different value (<your value>). This value needs to be set up in NVRAM as follows. Enter:
main> dev

B)

VOLUME 3 (4-66) O PTICS SERVICE P ROCEDURES

and enter the password:

boxer.dev

Enter:
r&d_main> nvram nvram> snv ND_MAX_TRANSMISSION <your value>

to obtain:
ND_MAX_TRANSMISSION updated... Parameter ND_MAX_TRANSMISSION | current <your value> | default | 160/$000000a0

Volume-Chapt er

POWER AND CONTROL SERVICE PROCEDURES

This chapter describes how to remove and replace RFI box assemblies and carry out any setups.

5.1 Starting the Service Procedures

5.1.1 RFI Box
See Figure 5.2 showing the location of each RFI box module. The RFI box holds the main system power and control modules previously described in Volume 2 Section 6.1. PSU 1: see Section 5.2.1 LSB Fan: see Section 5.2.1.1 (New procedure in Appendix B) Power Filter PCB: see Section 5.2.1.2 EODD PCB: see EODD PCB Replacement System PCB (LSB): see Section 5.2.1.3 Hard Disk Drive (HDD): see Section 5.2.1.4.

5.1.2 Engine Service Side

These include the following modules: Interlock box: see Mains filter box: see

5.1.3 Accessing the Assemblies

See Volume 2 Section 6.1.1 showing how to power and control assemblies.

4 4 4

Starting the Service Procedures ............................................................................... 5-1 Replacing RFI Box Modules ...................................................................................... 5-2 Replacing Interlock and Power Modules..................................................................5-2

VOLUME 3 (5-2) P OWER AND C ONTROL S ERVICE P ROCEDURES

SENSOR DISTRIBUTION PCB ASSEMBLY

24V DISTRIBUTION PCB ASSEMBLY DC CABLE MAINS INLET (10A 250V) POWER FILTER PCB POWER FILTER PCB INTERFACE DONGLE (OLD PCB ONLY)

PSU

EODD PCB

DISK DRIVE

EXTERNAL ALERT RELAY

DISK DRIVE MOUNTING BRACKET

SYSTEM (LSB) PCB INTERFACE SYSTEM (LSB) PCB

RFI BOX

LSB FAN

Figure 5.1 RFI box modules

5.2 Replacing RFI Box Modules

5.2.1 Power Supply Module (PSU1)
See Figure 5.2.

L UXEL P LATESETTER VOLUME 3 (5-3)

SLOT 1

SLOT 3

SLOT 4

SLOT 5

SLOT 6

-15V SENSE 0V 0V +36V WHITE/BROWN +5V RED 0V +24V WHITE/ ORANGE 0V +24V WHITE/ ORANGE 0V +15V YELLOW (+15V) VIOLET (-15V) 0V

Figure 5.2 PSU1 rear connections

1. Access the assembly inside the RFI box. 2. Disconnect the PSU AC and DC wires by removing their Faston connectors (the wires
are labelled) - see also Volume 2 Section 8.1.73.

3. From underneath the box, remove the 2-off posidrive screws holding PSU 1 mounting
plate and remove the assembly.

4. Detach the mounting plate from the PSU and replace the PSU.
NOTE: There are no setups or voltage adjustments to be made to the new PSU.

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.

5.2.1.1 LSB Fan Replacement

See Figure 5.1

1. Access the RFI box. 1. Detach the inline connector. 2. Remove the fan from the mounting bracket (posidrive screws). 3. When replacing the new fan, make sure it has the correct orientation.

5.2.1.2 Power Filter PCB Replacement

See Figure 5.1.

1. Access the RFI box and the Engine service side. 2. Remove the four interface connectors from the service side and detach the cables. 3. Detach the 4-off cables from the inside of the RFI box. 4. Detach the PCB from the rear and the side of the RFI box (4-off posidrive). 5. Replacement is the reverse of removal.

VOLUME 3 (5-4) P OWER AND C ONTROL S ERVICE P ROCEDURES

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.

EODD PCB Replacement

CAUTION: Wear an anti-static wrist-strap when handling the EODD.

See Figure 5.1.

1. Disconnect the four cable connectors. 2. Remove the PCB from the box mounting pillars (5-off posidrive screws). 3. Replacement is the reverse of removal. 4. There are no special checks for this PCB, but confirm system operation by running beam
coincidence checks and typical customer jobs. See also Volume 3 Section 4.2.

5.2.1.3 System PCB Replacement

NOTE: This section has new been replaced by the Guide Update in Appendix B.

See Figure 5.1.

1. Save the NVRAM parameters to the HDD using the main> command:
diagnostics/log_utils> save_nvram

2. Switch off the machine. 3. Disconnect the LSB interface connectors from the service end and remove the 3-off
posidrive screws to the PCB interface connector.

4. Disconnect the LSB cables from the interior of the RFI box, see Volume 2 Figure 6.15. 5. Remove the LSB by removing the 5-off posidrive screws holding the PCB to the box
pillars.

6. Replacement is the reverse of removal. 7. Make sure the Dongle PCB is swapped if it is not supplied. 8. Reboot the machine and download the firmware to the newly-installed LSB ensuring
that it matches the CAN node (slave) PCBs. If they do not match, the system may not function correctly.

9. Reboot the machine. If the terminal displays the following error message it is because
the the new LSB is not correctly configured for the machine type. If the machine boots without a problem then move to step 10).
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. Type machine at the prompt to get the following options:
main> machine Use <- or -> to select the machine type

B)

L UXEL P LATESETTER VOLUME 3 (5-5)

machine type: Luxel Vx96000CTP/b8_auto_web (Violet B1 Auto Web)

C)

Use the arrow keys to change the machine type to select the machine type:

Luxel V6000CTPM/b4_manual_punch (Violet B2 Manual Punch) Luxel Vx6000CTPM/b4_manual_web (Violet B2 Manual Web) Luxel V6000CTPM/b4_manual_punch (Violet B2 Manual Punch) Luxel Vx9600CTPM/b8_manual_web (Violet B1 Manual Web) Luxel V9600CTPM/b8_manual_punch (Violet B1 Manual Punch) Luxel Vx9600CTP/b8_auto_web (Violet B1 Auto Web) Luxel V9600CTP/b8_auto_punch (Violet B1 Auto Punch) Luxel P-9600CTPM/boxer8_manual (Green B1 Manual Punch) Luxel P-9600CTP/boxer8_plate (Green B1 Auto Punch) Luxel F4080/sumo4_film (Sumo 4 page config.) Luxel F9000/sumo8_film (Sumo 8 page config.) Luxel/production (Production config.) UNKNOWN D) select the correct machine type and press [Return].

10. Reboot the machine and stop at the second Ctrl-c. 11. Run the command, restore_nvram, from Log_utils to restore the parameters from HDD. 12. Update Configuration data from the Registry using the diagnostics command:
test/registry> update_registry system

and follow the screen instructions.

13. Check if the revised details are valid by running the Reg_power test:
test/registry> reg_powerup

14. Expose a test page and check for quality.

5.2.1.4 HDD Replacement

See Volume 2 Section 6.6.3. If the HDD is to be replaced, you will lose all HDD files and will need to regenerate them after replacement. If the LSB and HDD is to be replaced, you will lose all NVRAM parameters, as well as other system information, and this data will need to be entered manually after replacement. If the two are to be replaced together, then before replacing either assembly, enable capture text and record the system serial number, build date and final test date using the diagnostic display_registry, see Volume 2 Section 1.8.3. After replacement, when running diagnostic update_registry, you will be asked for this information. Also, you will need to manually restore all NVRAM parameters using the Savelog NVRAM file and the snv command in the development menu.

Store Required HDD Files

1. Keep a hard copy of the cassette database by enabling capture text and running the
command:
service/dbases/cassette_dbases/dumpc

2. Create a text file containing the NVRAM values using the command:
main> tnv

VOLUME 3 (5-6) P OWER AND C ONTROL S ERVICE P ROCEDURES

then transfer the text file to the RIP PC using Savelog.

Replace the HDD

1. Disconnect the PWR and DATA cables from the two drives. 2. Remove the 1-off posidrive screw holding the HDD mounting bracket to the RFI box. 3. From the front of the RFI box, remove the 6-off posidrive screws holding the disk drive
to the bracket and remove the complete assembly.

4. Configure the new drive for the correct ID. The drive's default factory setting should be
correct.

5. Replace the drive and HDD assembly.

Restore and Check HDD Files

1. Save the NVRAM values:
log utils> save_nvram

2. Update the System Registry, see Volume 2 Section 1.11. 3. Restore the PIs, see Volume 2 Section 1.13. 4. Transfer the Media Database from the RIP server using information in the relevant RIP
manual.

5. Restore the Cassette Database from the Change Cassette menu on the MMI. The original
database settings are stored in the old HDD dumpc file.

6. Recreate the ND char file:

log_utils> nd_char

7. Check that the correct file has been replaced on the new HDD.
If the HDD and LSB are being replaced, then before storing the required HDD files, enable capture text and run the diagnostic display_registry system.

5.3 Replacing Interlock and Power Modules

5.3.1 Mains Filter Box
This box is located at the service end underneath the mains on/off switch. See also Volume 2 Section 6.2.2.
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.

In the event of failure replace the complete assembly as an FRU.

5.3.2 Interlock Box

See Figure 5.3 and Volume 2 Section 6.3.5.

L UXEL P LATESETTER VOLUME 3 (5-7)

FUSEHOLDERS AND 3-OFF FUSES (SEE NOTE) INTERLOCK CONTACTOR INTERLOCK MONITORING MODULE TERMINAL BLOCK COMPRESSOR RELAY (BV31) PWR 1 INTERLOCKS

SHUTTER (LASER ON/OFF)

END STOP

SURGE SUPPRESSOR RAIL PWR 3 PWR 2 POWER IN EMERGENCY VAC

PSU (30W +24V) PSU MAINS COVER

ON/OFF SWITCH (CIRCUIT BREAKER) VAC PUMP RELAY (BV5) VAC PUMP (2) MAINS_DIST

OVERCURRENT CIRCUIT BREAKER 24V FUSE (0.5A 250V)

MAINS_RFI_IN

COMPRESSOR

LED DIAGNOSTICS

VAC PUMP (1)

Figure 5.3 Interlock box - general view

Items inside this box are replaced as separate FRUs.

VOLUME 3 (5-8) P OWER AND C ONTROL S ERVICE P ROCEDURES

APPENDIX

QUICK REFERENCE DATA

This appendix provides a quick reference for the service engineer to operate sensors, solenoids and motors.

A.1

4 4 4 4 4

Useful Service Commands ..................................................................................................... A-1 Useful Service Sensor Tests .................................................................................................. A-2 Sensor Listing.......................................................................................................................... A-2 Solenoid Listing....................................................................................................................... A-4 Motor Listing ............................................................................................................................ A-4

Useful Service Commands

Table A-1 to Table A-4 list some of the more useful service commands for actuating motors, sensors and solenoids.
Table A.1 Useful Service commands

Command actuators/set bm28 on actuators/set bm28 off actuators/set bm27 on actuators/set bm27 off actuators/set bm20 on actuators/set bm20 off actuators/set bm23 off actuators/set bm23 on actuators/set_drv bm22 on actuators/set_drv bm22 dis actuators/set bm25 off actuators/set bm25 on actuators/set bv20 on actuators/set bv20 off actuators/set_drv bm24 on

Device
Z-direction Z-direction X-door X-door Cassette forward Cassette forward Nudger lift Nudger lift Nudger rollers Nudger rollers Retard Retard Diverter Diverter Interleave rollers

Sensor/Motor
BM28,BS63,BS70 BM28,BS63,BS70 BM27,BS62,BS71 BM27,BS62,BS71 BM20,BS41,BS42 BM20,BS41,BS42 BM23,BS45,BS46 BM23,BS45,BS46 BM22 BM22 BM25,BS56,BS57 BM25,BS56,BS57 BV20 BV20 BM24

Result
Z-direction up Z-direction down X-door up X-door down Cassette forward Cassette reverse Nudger down Nudger up Nudger rollers rotate Nudger rollers stop Retard down Retard up Diverter down Diverter up Interleave rollers rotate

A-2 Q UICK R EFERENCE DATA

Table A.1 Useful Service commands (Continued)

actuators/set_drv bm24 off motors/set stack motors/move 2000 f 400 motor/offstation 0 400
Interleave rollers Stack height Stack height Stack height BM24 BM21 BM21,BS61 BM21,BS44 Interleave rollers stop Select stack motor Moves stack up Moves to home

A.2 Useful Service Sensor Tests

Table A.2 Useful service sensor tests
Command sensors/read_s bs47 sensors/read_s bs65 actuators/set bv20 on sensors/read_s bs53 sensors/read_s bs66 sensors/read_s bs43 sensors/read_con ip Device
Stack position Cassette at nudger Diverter Paper tensioner Interleave nip clear Cassette empty Cassette IDs

Sensor/Motor
BS47 BS65 BV20 BS53 BS66 BS43 BS36 to BS40

Result
Paper in front (on); paper removed (off) Hold in microswitch (off); release microswitch (on) Paper under diverter (down); remove paper (up) Paper under diverter (on); remove paper (off) Paper under diverter (on); remove paper (off) Paper in front (off): remove paper (on) Paper in front (off); paper removed (on)

A.3 Sensor Listing

Table A.3 Sensors
Sensor BS1 Description
INPUT ENTRANCE INPUT EXIT

FHMB
FHMB 1

Sensor BS41

Description
CASS FWD LIMIT CASS REV LIMIT CASS EMPTY STACK HEIGHT HOME NUDGER DWN NUDGER UP

FHMB
FHMB 2

Sensor BS81

Description

FHMB

BS2

FHMB 1

BS42

FHMB 2

BS82

BS3

PLATE IN PUNCH OUTPUT ENTRANCE

FHMB 4

BS43

FHMB 3

BS83

BS4

FHMB 4

BS44

FHMB 3

BS84

BS5

OUTPUT EXIT PUSH BAR HOME

FHMB 4

BS45

FHMB 3

BS85

BS6

FHMB 4

BS46

FHMB 3

BS86

BS7

BS47

STACK HEIGHT NUDGER DETECT RETARD MADE PLATE PRE DIV

FHMB 3

BS87

BS8

PUNCH MOTOR ON PUNCH MTR OFF REG MOTOR OUT REG MTR IN

FHMB 1

BS48

FHMB 3

BS88

BS9

FHMB 1

BS49

FHMB 3

BS89

BS10

FHMB 4

BS50

FHMB 3

BS90

BS11

FHMB 4

BS51

PAPER POST DIV TOP

FHMB 3

BS91

L UXEL P LATESETTER A-3

Table A.3 Sensors (Continued)

BS12
CENTERING RH CENTERING LH CENTERING HOME PUSH BAR FWD FHMB 4

BS52

PARK PRE INPUT LAZY LOOP

FHMB 3

BS92

BS13

FHMB 4

BS53

FHMB 3

BS93

BS14

FHMB 4

BS54

BS94

BS15

FHMB 1

BS55

PAPER POST DIV UND RETARD UP RETARD DOWN PLATE PAST DIVERTER

FHMB 3

BS95

BS16 BS17

BS56 BS57

FHMB 3 FHMB 3

BS96 BS97

BS19

BUFFER ENTRANCE BUFFER EXIT FAST PHOTO DET

FHMB 4

BS59

FHMB 3

BS99

BS20

FHMB 4

BS60

BS100

REG PIN HOME (WEB)

FHMB 4

BS21

FHMB 4

BS61

STACK HEIGHT TOP X DIR DOOR UP Z DIRECTION UP

FHMB 3

BS101

BS22

BS62

FHMB 2

BS102

BS23

BS63

FHMB 2

BS103

REG PIN OUT (WEB) REG PIN CONTINUITY (WEB)

FHMB 4

BS24

BS64

BS104

FHMB 4

BS25

BS65

CASSETTE AT NUDGER INTER NIP CLEAR

FHMB 3

BS105

BS26

BS66

FHMB 3

BS106

BS29

BS69

BS109

SWING ROLLER HOME (WEB) SWING ROLLER IN (WEB)

FHMB 4

BS30

ELEVATOR OVER TOP ELEVATOR OVER BTM ELEVATOR SHELF 1 ELEVATOR SHELF 2

FHMB 2

BS70

Z DIR DOWN

FHMB 2

BS110

FHMB 4

BS31

FHMB 2

BS71

X DIR DOOR DWN CASS DOOR CLOSED ELVATOR MTR DISABLED VECTOR ALARM

FHMB 2

BS111

BS32

FHMB 2

BS72

FHMB 2

BS112

PUSH BAR FWD (WEB) MANUAL CENTERING HOME MANUAL CENTERING CONT

FHMB 4

BS33

FHMB 2

BS73

FHMB 2

BS113

FHMB 1

BS34

ELEVATOR SHELF 3

FHMB 2

BS74

FHMB 2

BS114

FHMB 1

BS35

BS75

VECTOR OVERLOAD FRONT DOOR DOCKING RH DOCKING LH

FHMB 2

BS115

BS36

CASS ID 1

FHMB 2

BS76

FHMB 2

BS116

MANUAL PLATE PUSHER HOME

FHMB 1

BS37 BS38

CASS ID 2 CASS ID 3

FHMB 2 FHMB 2

BS77 BS78

FHMB 2 FHMB 2

BS117 BS118
MANUAL PLATE ON PLATEN OPTO FHMB 4

BS39

CASS ID 4

FHMB 2

BS79

CHAD TRAY

FHMB 4

BS119

A-4 Q UICK R EFERENCE DATA

Table A.3 Sensors (Continued)

BS40
CASS ID 5 FHMB 2

BS80

MIXER FAN DETECT

FHMB 1

BS120

DRUM TEMPERATURE

A.4 Solenoid Listing

Table A.4 Solenoids
Solenoid BV1 BV2 Description FHMB Solenoid BV21 BV22
CASS DOOR LOCK PLATE FEED PUMP 24V ON/OFF DOCKING LIGHT FHMB 2

Description

FHMB

Solenoid BV41 BV42

Description

FHMB

AIR KNIFE SOL

FHMB 4

BV3

MIXER FAN RELAY

FHMB 1

BV23

FHMB 3

BV43

BV4 BV5
DRUM VAC SOL EXT ALERT RELAY FHMB 4

BV24 BV25

FHMB 3 FHMB 2

BV44 BV45

BV8

FHMB 1

BV28

BV48

BV9 BV10

BV29 BV30
DIVERT VALVE BLOW COMPRESSOR LEADING EDGE VALVE FHMB 4

BV49 BV50

BV11

BV31

FHMB 4

BV20

DIVERTER

FHMB 3

BV40

FHMB 1

A.5 Motor Listing

Table A.5 Motors
Motor BM1 Description
INPUT BAND

FHMB
FHMB 1

Command
actuators>set_drv

Motor BM21

Description
STACK HEIGHT NUGER & TAKAWAY NUDGER LIFT INTERLEAVE DRIVE RETARD DROP ELEVATOR

FHMB
FHMB 3

Command
motors>setmotor

BM2

PUSH BAR

FHMB 1

motors>setmotor

BM22

FHMB 3

actuators>set_drv

BM3

CENTERING

FHMB 4

motors>setmotor

BM23

FHMB 3

actuators>set

BM4

PUNCH

FHMB 1

actuators>set

BM24

FHMB 3

actuators>set_drv

BM5

REG PIN (PUNCH) OUTPUT (DC)

FHMB 4

actuators>set

BM25

FHMB 3

actuators>set

BM6

FHMB 4

actuators>set_drv

BM26

FHMB 2

medtran>move_elevat or actuators>set actuators>set

BM7 BM8

BUFFER

FHMB 4

motors>setmotor

BM27 BM28

X DIR DOOR Z DIR CTRL

FHMB 2 FHMB 2

L UXEL P LATESETTER A-5

Table A.5 Motors (Continued)

BM10
MAN/SEMI PLATE CENTERING MAN/SEMI PLATE PUSHER FHMB 1 motors>setmotor

BM30

BM11

FHMB 1

motors>setmotor

BM31

BM16

BM36

REG PIN (WEB) SWING ROLLER (WEB) MAN/SEMI OUTPUT (STEPPER)

FHMB 4

actuators>set

BM17

BM37

FHMB 4

actuators>set

BM18

BM38

FHMB 4

motors>setmotor

BM19 BM20
CASSETTE FWD FHMB 2 medtran>load_cas sette

BM39 BM40

A-6 Q UICK R EFERENCE DATA

APPENDIX

GUIDE TECHNICAL UPDATES

This SIO appendix provides the latest technical descriptions and procedures to current Issue 04 for engineers previously trained with Issue 03 (or earlier). Once the pages are downloaded and printed, insert them into your Engineers Reference Guide.

B.1

4 4 4 4 4

Luxel System PCB Replacement ........................................................................................... B-1 Laser Temperature and Humidity Control............................................................................. B-4 Aperture Control Replacement .............................................................................................. B-6 Punch, Registration and Centerer (Fuji)................................................................................ B-9 Vacuum and Air Control........................................................................................................ B-16

Luxel System PCB Replacement

CAUTION: Wear an anti-static wrist-strap when handling the System PCB.

See Volume 2 Figure 6.8.

1. Save the NVRAM parameters to the HDD using the main> command:
diagnostics/log_utils> save_nvram

2. Switch off the platesetter and the RIP PC. 3. Disconnect the LSB interface connectors from the service end and remove the 4-off
posidrive screws to the PCB interface connector. Loosen the LSB fan mounting screws and remove the LSB fan for access to the LSB.

4. Disconnect the LSB cables from the interior of the RFI box, see Volume 2 Figure 6.15. 5. Remove the LSB by removing the 5-off posidrive screws holding the PCB to the box
pillars.

6. Replacement is the reverse of removal.

NOTE: The dongle, if fitted on the old PCB, is not required on the new PCB.

7. Power on the RIP PC and start the diagnostics Hyperterminal.

B-2 G UIDE TECHNICAL U PDATES

8. Reboot the Engine and stop at the first [Ctrl-c] message.

A)

Type machine at the prompt to get the following options:

main> machine Use <- or -> to select the machine type machine type: Luxel Vx96000CTP/b8_auto_web (Violet B1 Auto Web)

B)

Use the arrow keys to change the machine type:

Luxel V6000CTPM/b4_manual_punch (Violet B2 Manual Punch) Luxel Vx6000CTPM/b4_manual_web (Violet B2 Manual Web) Luxel V6000CTPM/b4_manual_punch (Violet B2 Manual Punch) Luxel Vx9600CTPM/b8_manual_web (Violet B1 Manual Web) Luxel V9600CTPM/b8_manual_punch (Violet B1 Manual Punch) Luxel Vx9600CTP/b8_auto_web (Violet B1 Auto Web) Luxel V9600CTP/b8_auto_punch (Violet B1 Auto Punch) Luxel P-9600CTPM/boxer8_manual (Green B1 Manual Punch) Luxel P-9600CTP/boxer8_plate (Green B1 Auto Punch) Luxel F4080/sumo4_film (Sumo 4 page config.) Luxel F9000/sumo8_film (Sumo 8 page config.) Luxel/production (Production config.) UNKNOWN
NOTE: Web refers to a machine without a punch; manual refers to a Manual or SemiAutomatic machine; Auto refers to a Fully-Automatic machine.
C) D)

Select the correct machine type and press [Return]. Type y at the Reset Now? prompt, then stop at the first [Ctrl-c] message. Make sure the boot firmware is the same as the other CAN BUS PCBs. If not, download the correct boot firmware to match the other PCBs. This is the file named b8_auto_punch_ssb_boot.hex for all variants (V-9600, Vx-6000, Semi-Automatic, Manual and Fully-Automatic). Download the application firmware to the LSB to match the other PCBs. The filename for this file includes the machine variant and ends as _ssb_recorder.hex.

9. Download the firmware to the LSB only.

A)

B)

CAUTION: Make sure the firmware on the newly-installed LSB matches the CAN node PCBs. Failure to match will cause the system to malfunction.

10. Reboot the machine and stop at the second [Ctrl-c]. 11. Run the following command to restore the parameters from HDD:
log_utils> restore_nvram

12. Update Configuration data from the Registry using the diagnostics command:
test/registry> update_registry

and follow screen instructions. Check for the message: Update Registry: PASSED.

13. Check if the revised details are valid by running the Reg_power test:
test/registry> reg_powerup

L UXEL P LATESETTER B-3

14. Reboot the machine and the RIP PC. 15. Expose a test page and check for quality.

B-4 G UIDE TECHNICAL U PDATES

B.2 Laser Temperature and Humidity Control

B.2.1 Operation
See Volume 2 Figure 5.3 showing the location of the temperature and humidity module inside the optics base. Temperature and humidity levels of air around the laser blocks, shown in Volume 2 Figure 5.3, are monitored from a Temperature/Humidity Sensor PCB mounted on a bracket located inside the laser enclosure. The PCB includes separate temperature and humidity sensors shown in Figure B.1. The purpose of the module is to detect when the moisture content of air in contact with the laser block is high enough to cause condensation. The laser block is regulated at 25C so that air surrounding the block surface will be cooled to 25C. Moisture content of air is measured by its dew point temperature. Dew point temperature is defined as the temperature to which air would have to cool in order to reach saturation. A state of saturation exists when air is holding the maximum amount of water vapour possible at the existing temperature and pressure. If the dew point of air surrounding the laser block is above 25C, water will condense onto the surface of the block. The system uses measured air temperature to calculate the air humidity at which condensation would occur. If measured humidity is within 10% RH of a calculated value then the laser temperature regulator is switched off. Switching off the regulator allows the block to warm up to the same temperature as its surroundings, so that air coming into contact with the block is no longer cooled. Since air is not cooled, condensation does not occur. The humidity sensor in each module is individually calibrated and has two associated NVRAM parameters: RH ZERO OFFSET: voltage out at 0% RH RH SLOPE: the rate of change of output voltage with relative humidity. If the module is replaced, new NVRAM values are always re-entered, see Section 2.3 on page B-5. Current temperature and humidity levels are read using the main diagnostics laser menu (development) commands:
read_optics_temp read_optics_humidity

Specific error codes for indicating dew point warning levels are described in the MMI Errors Guide. See also Volume 2 Figure 5.18 showing the module connection to the VBOMB.

L UXEL P LATESETTER B-5

TP1 TEMP SENSOR

TP2

HUMIDITY SENSOR PL2

Figure B.1 Temperature and humidity PCB layout

B.2.3

Module Replacement

CAUTION: Always switch off the machine BEFORE removing the disconnecting the Temperature/Humidity PCB. CAUTION: Do not touch the humidity sensor shown in Figure B.1.

See Volume 2 Figure 5.2.

1. Shutdown the platesetter. 2. Note the new NVRAM values marked on the replacement module. 3. Access the laser modules enclosure (fit the PAT and optics service manifold). 4. Disconnect the connector from the temperature/humidity module. 5. Remove the 2-off Allen screws holding the module to the base. 6. Refit the new module and the module enclosure. 7. Switch on the platesetter and enter the new NVRAM values for:
RH_ZERO_OFFSET RH_SLOPE

B-6 G UIDE TECHNICAL U PDATES

B.3 Aperture Control Replacement

The aperture mechanism will be supplied fitted with a 48 res lens. During manufacture the optics base V-groove stands are optimised for the fitted lens. It will be necessary to move the original lens (L3) to the new aperture mechanism, otherwise there may be an excessive 48 res registration error visible on the plate.

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.

B.3.2

Replacement Procedure

1. Set the aperture to the 96 res position

optics/motors/move_motors> beam_res_pos 96

2. Power down the machine. 3. Remove the 11-off screws holding the optics lid in place and immediately fit the
PAT Optics Service Manifold to prevent optics contamination.

4. Remove 5-off screws from the Aperture cover and take out carefully, to avoid 5. Disconnect the Aperture Home sensor cable (red sleeve) from the sensor. 6. Disconnect the Aperture motor cable (black sleeve) from the motor. 7. Remove the 4-off screws holding the Aperture mechanism to the Optics Base
and remove the mechanism.

snagging the cables. These are most easily removed using straight-ended T-bars.

8. Note the orientation of the lens before removing as it is possible to fit it on

backwards. Mark the lens holder to indicate its orientation.

9. Using a flat-bladed screwdriver, supporting the lens from below, undo the
shoulder bolt and retain the spring and washer. Repeat with the new mechanism.

10. Replace the old lens into the new mechanism.

CAUTION: Do not to cross thread the shoulder bolt in the lens hole and fit the lens the correct way around.

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

13. Power up the machine.

B.3.3

Setting up Procedure

1. The following operations assume a 2-beam machine. If it is a single beam, use

the available beam.

2. The X and Y beams need to be centered on the 72 res aperture. 3. From diagnostics run:
development/nvram> snv LD_X_MRES_WORKING_DRIVE_DAC 1000 development/nvram> snv LD_Y_MRES_WORKING_DRIVE_DAC 1000

4. Switch on both the X beam (LD1) and the Y beam (LD3) lasers, set the ND

mechanism to 80. This is to allow laser light to pass, but will reduce the power of the beam and hence the laser hazard. A higher ND reading can be chosen if necessary to view the beams easily. The LPD is closed to avoid laser light entering the drum, and so it is ready to read laser power.
optics/motors/move_motors> close_pos_lpd optics/laser> lenable 1 drive 72 optics/laser> lenable 3 drive 72 optics/laser> x_beam_enable
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 reading, 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.
laser> ldisable 1 laser> ldisable 3

18. Turn off the lasers:

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. procedures, see Volume 3 Table 4.1.

22. Run exposure calibration again (run it as part of the aperture assemblies set up 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

B.4

Punch, Registration and Centerer (Fuji)

This punch (referred to as Fuji In-house) is an advanced design on the old and new versions of the Billows punch. It uses similar ID numbering for motors and sensors, and includes the registration, centerer and punch modules that operate in a similar way to the Billows punch. New features for the Violet punch include: Fabricated in aluminium as a complete casting. Chad control using Beryllium copper wiper strips to prevent chad collecting inside the die. Accessible sensors and motors for improved servicing. Facility to extend the service life of the punch crop pins.

B.4.1
B.4.1.1

Punch Assembly Removal

Accessing the Assembly

See Figure B.2 and Figure B.3. A complete punch assembly (including motors, cables and drag chain) is supplied if the old punch needs to be replaced. The assembly sits on two dowels fitted to the drum casting to allow for accurate location. You do not need to remove the punch motor beforehand. Remove the complete assembly as follows:

1. Move the traverse to the user end. 2. Lower the Buffer to its service position, see Volume 3 Section 2.5.1. 3. Protect the inside of the drum with any heavy-duty material that can take the
dropped weight of the punch.

4. Remove the stretcher panel on the Buffer side of the Engine by removing the 2off screws at the top of the optics base cover and the 4-off M5 Allen bolts holding the panel in place.

5. Remove the output module, see Volume 3 Section 2.4.4.1.

B.4.1.2

Removing the Assembly

CAUTION: If you are replacing a Billows on a Green machine with a Fuji punch, then the output exit guide needs to be replaced and the output raised to avoid fouling the centering arms.

B-10 G UIDE TECHNICAL U PDATES

S10

CENTERING MOTOR (BM3) REG PIN DC MOTOR

S14 CENTERING ARM (RH)

CENTERING ARM (LH)

S13 S12 PIN/DIE/ CHAD WIPER BS3

A
PUNCH MOTOR (BM4) BS8/9

CENTERING MOTOR S11

REG PIN CAM

NOTE: S12/S13 FITTED TO CENTERING FINGERS ON HIDDEN SIDE REG PIN ACTUATING ARM

REG PIN DC MOTOR (BM5)

UNDERNEATH VIEW ON ARROW A

CENTERING PINION

ACTUATING SHAFT

Figure B.2 Punch, registration and centerer assemblies

6. Remove the punch motor (optional). 7. Disconnect the following sensor and motor cables to the punch:
A) B) C)

punch motor and sensors (service side) registration motor and sensors (rear of Engine) centering motor and sensors (rear of Engine and both ends) Remove the 8-off M6 bolts set in pairs. Using one person at each end, lift out the assembly. Lift by first raising the user end slightly. Avoid lifting from the drag chain. Check that the two dowels are still in position in the drum.

8. Remove the punch assembly from the drum as follows:

A) B)

C)

9. The complete assembly is serviced by laying it between the two cutouts on the
wooden transit fittings used for the Autofeeder.

L UXEL P LATESETTER B-11

M6 BOLTS

M6 BOLTS

LOWER BEAM SUPPORT

DRUM CASTING

DOWEL

LOWER BEAM SUPPORT

SERVICE SIDE PLAN VIEW OF DRUM CASTING

Figure B.3 Removing the punch assembly

B.4.1.3

Complete Punch Replacement

1. If you are fitting a new punch option or complete assembly, check that it has not
been damaged during transit.

2. Make sure the drum surface is fully protected by heavy cardboard. 3. Position the new punch on the dowels (they should fit through the guide holes).
The punch motor will be part of the assembly which makes this operation more awkward. Avoid knocking the carriage flywheel. middle of the punch.

4. Screw in (but do not tighten) the 8-off M6 bolts from the outside towards the 5. Manually check that a large plate can enter and exit the punch correctly without
scratching. Check that the leading edge is picked up by the first output module roller. the aluminium fixing hole threads in the drum are easily damaged.

6. Tighten the M6 bolts from the centre outwards. Do not overtighten the bolts 7. Reconnect all cabling on the service side and the registration/centerer motors.

B.4.1.4

Punch Adjustments and Checks

Visual plate checks are recommended after approximately 35,000 punch operations have been completed. Use the command to check the NVRAM parameter:
diagnostics/log_utils> dis_stats

B-12 G UIDE TECHNICAL U PDATES

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.

B.4.1.4.1 Visual Plate Punch Check

1. Discuss with the customer any issues or problems that have appeared since the
last service visit.

2. Run a punch job from the RIP. 3. Place the exposed plate on a flat surface and check the following:
A) B)

Punch crops are centred, see Volume 3 Figure 1.8.2.3. Punch crops are the correct depth: standard punch depth at 12 mm, custom at 11 mm crops are equal depth when measured between left and right (specification is 50 microns) crops are cleanly cut without debris in corners or burrs (See `Replacing the Punch Pins' on page B-12. plate lead edge to the image start position is inside the specification, see Volume 3 Section 1.8.3.3. 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.

B.4.1.4.2 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.

B.4.1.5

See Figure B.4. The Fuji punch pins are able to cut at both ends by removing, turning and replacing them during a service visit after checking if there are signs of burring around the punch holes. Use the following procedure to obtain a clean cutting edge:

1. Remove the punch support plate and motor using the procedure in See `Removing the
Punch Motor' on page B-13.

4 4 4 4 4

Replacing the Punch Pins

L UXEL P LATESETTER B-13

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

Figure B.4 Servicing the punch pins

B.4.1.6

Removing the Punch Motor

This procedure is completed from the service side without removing the complete punch assembly. See Figure B.5.

1. Disconnect the inline cables to the motor and sensors (BS8 and BS9).

B-14 G UIDE TECHNICAL U PDATES

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.

BS8 (ON)

PUNCH MOTOR SUPPORT PLATE

MOTOR/GEAR (BM4)

BS9 (OFF)

Figure B.5 Punch bracket and motor

B.4.1.7

Replacing the Chad Wipers

See Figure B.6. Chad wipers, made of Beryllium copper, are replaced every six months to avoid the build-up of chad at the punch exit. Use the following procedure:

1. Remove the punch deflector shield (3). 2. Remove the wiper with its snap rivet.
If the punch is a a DS type then trim the wiper for the round punch holes, as shown in Figure B.6.

3. Refit the wiper and rivet making sure it is seated on top of the bracket.
Refit the shield.

L UXEL P LATESETTER B-15

4. Run a punch job from the RIP and check that chad does not drop into the drum.

SNAP RIVET

CHAD WIPER

PUNCH DIE

6 mm CUT CUT CHAD WIPER WIPER MOUNTING BRACKET

DS (ROUND) WIPER TRIM

CHAD DEFLECTOR SHIELD

Figure B.6 Removing the chad wiper

B-16 G UIDE TECHNICAL U PDATES

B.5 Vacuum and Air Control

NOTE: Replace the old version of Volume 2 Chapter 7 with the new version issued in this Guide (04).

I NDEX A
Absolute Limit sensor check, 3-1-12 Absolute Phase Actuators Air Knife
check, 3-4-45 description, 2-4-13

Billows

functional description, 2-5-12 Centerer assembly, 2-3-96 description, 2-3-93 Punch control mechanism, 2-3-94 Registration Module description, 2-3-93 Registration Pins assembly, 2-3-95

compressor version, 2-7-18 fan blower version, 2-7-19 replacement, 2-7-20 Antistatic brush, 2-3-56

Booting Booting up Buffer

sequence, 2-1-4 sequence of loading, 2-1-2 accessing assemblies, 3-2-60 Buffer to Engine interconnections, 2-3106 control assemblies, 2-3-102 drive belts, 3-2-62 lowering the buffer, 3-2-57 plate handling, 2-2-11 plate handling assemblies, 2-3-102, 2-3104 plate handling operations, 2-2-20 plate handling sequence, 2-2-42 upper cover removal, 3-2-60

Antistatic kit, 1-3-25

earthing (grounding), 1-3-25 enclosures, 1-3-25 field handling station, 1-3-25 functional description, 2-5-15 replacement, 1-B-6 loading firmware, 2-1-66

Aperture

Application Autofeeder

alignment with PTM, 3-2-7 control box, 2-3-9 drive assemblies, 2-3-27 elevator assemblies, 2-3-24 inverter, 2-3-11 motors, 2-3-22 multi-cassette housing, 2-3-25 plate handling, 2-2-1 plate handling assemblies accessing, 3-2-4 plate handling sequence, 2-2-21 PTM interconnections, 2-3-105 sensors, 2-3-23 solenoids, 2-3-22

C
Cables
Alert, 2-8-26 CAN 2, 2-8-3 CAN3, 2-8-10 CAN3 INT, 2-8-13 CAN5, 2-8-8 disk drive power, 2-8-2 Elevator Control, 2-8-28 Elevator In, 2-8-29 Elevator Lock, 2-8-30 EOD, 2-8-2 Feed Interlocks, 2-8-11 FHMB Power, 2-8-8 interlocks, 2-8-1, 2-8-5 Mains, 2-8-2 Mains Elevator In, 2-8-29 MMI, 2-8-4 Power 3, 2-8-12 Processor, 2-8-32 Processor Comms, 2-8-44 Vac Pump, 2-8-11

B
Baffle Ball Cage
operation, 2-4-8 replacement, 3-3-4 replacement, 3-3-11

Beam Co-incidence, 2-1-30 Beam Combiner

auto setup, 3-4-42

1-2 I NDEX

Calibration CAN

VBOMB optics cabling, 2-5-28 exposure, 3-4-51 Configuration files, 2-1-62 network control, 1-2-33 assemblies, 2-3-30 database diagnostics, 2-1-58 solenoid, 2-3-20

Cassette

Cassette Door

Error Codes, 2-1-10 global commands, 2-1-14 initialisation, 2-1-4 introducing, 2-1-1 log utilities, 2-1-19 scripts, 2-1-18 see Main Diagnostic see Main Diagnostics introducing, 2-1-12 self tests, 2-1-8 starting, 2-1-13 system output data path checks, 2-1-9 Test Menu, 2-1-27

Cassette Forward

assembly, 2-3-52 Cassette ID PCB, 2-3-45

Disk Drive

CAUTIONS
disposable wrist strap, 1-3-25 exposed components, 1-3-24 Health and Safety at Work, 1-3-1 unearthed surface, 1-3-25 Chad Tray, 2-3-101

replacement, 3-5-5 description, 2-6-29 diagnostic commands, 2-1-46 functional description, 2-6-29 storing config data, 2-1-64

Distribution PCBs
Engine, 2-3-71 PTM, 2-3-43 DLA Curtain, 1-3-5 laser radiation hazard, 1-3-5 opacity to blue light, 1-3-5 Warnings, 1-3-5 DLA Room, 1-3-4 laser warning notice, 1-3-4 red warning light, 1-3-4

Coincidence Beam X Coincidence Beam Y

setup, 3-4-42 setup, 3-4-44

Configuration Data Files Covers

menu commands, 2-1-22 using the utilities, 2-1-60 opening, 3-1-3

Dongles

Drive Rail Wiper Drum Drum Vacuum

description, 2-6-29 cleaning, 3-1-7 replacement, 3-3-7 assembly, 2-3-90 removing end caps, 3-2-28 interlock box circuits, 2-6-11 Dust contamination, 1-3-18

D
Database Debug
diagnostic commands, 2-1-58 introduction, 1-2-15 using, 2-1-16

Dust Contamination

Deflection Absolute Phase, 3-4-45 Deflection Amplitude Beam Y

setup, 3-4-47

E
Edge Detect
description, 2-4-18 function check, 3-1-24 sensor offset, 3-1-26 laser, 3-3-13 replacement, 3-3-13 setup, 3-3-16

Devices Diagnostics
Safety, 1-3-17 Boot-up tests description, 2-1-4 Commands scripts, 2-1-18 debug, 2-1-16

Edge Detect PCB

L UXEL P LATESETTER 1-3

Electro-Optic Deflector
functional Description, 2-5-11 replacement, 3-4-22

Feed Head
assembly, 2-3-55

Elevator

FHMB

absolute limit safety switch, 2-3-22 chains, 3-2-13 contactor, 2-3-14 control box, 2-3-9 drive, 2-3-27 Elevator Control PCB, 2-3-16 Elevator Distribution PCB, 2-3-18 frame, 2-3-26 interlock controls, 2-3-14 motor, 2-3-22 functional description, 2-6-9 see Imagining Engine, 1-1-7 SSB monitoring, 1-2-30 replacement, 3-5-4 connectors, 2-6-24 functional description, 2-6-23

operation, 1-2-7 PCB description, 1-2-5 replacement, 3-2-3 connectors, 2-3-62 device controls, 2-3-65 PCB description, 2-3-62 connectors, 2-3-35 device controls, 2-3-37 PCB description, 2-3-34 connectors, 2-3-40 device controls, 2-3-42 PCB description, 2-3-38 connectors, 2-3-66 device controls, 2-3-70 PCB description, 2-3-66 creating, 3-4-55

FHMB (1)

FHMB (2)

Emergency Stop Control Engine

FHMB (3)

Environment EODD

FHMB (4)

EODD PCB EODHV

Film Comparison Ruler Firmware Focus Adjust

upgrading, 2-1-66

functional description, 2-5-17 replacement, 3-4-25 Transformer (HV) replacement, 3-4-25

Equipment Error Codes

Unattended, 1-3-17 listing, 2-1-10 self tests, 2-1-7 sets of, 2-1-7 fatal error closedown sequence, 2-1-11 recovering from, 2-2-45

Focussing Lens Fuses

functional description, 2-5-14 setup, 3-4-38 cleaning, 3-1-5 FHMB (1), 2-3-36, 2-3-41, 2-3-63 FHMB (4), 2-3-68 LSB, 2-6-27 SSB, 2-6-24 system fuses, 2-6-20

Error Handling EVT

G
Gear Segment
replacement, 3-2-36

diagnostic commands, 2-1-31 Exposure Calibration, 3-4-51

F
Fans Fast Photo Detect
description, 2-5-25 replacement, 3-4-30 RFI box, 2-6-20

H
Hazards, 1-3-17
Chemical, 1-3-18 Laser Radiation, 1-3-17 Spinner, 1-3-18

HDD

1-4 I NDEX

Health and Safety at Work, 1-3-1

Cautions, 1-3-2 Clothing and Jewellery, 1-3-2 Equipment and Tools, 1-3-2 site safety, 1-3-2 Warnings, 1-3-2

configuration files, 2-1-64

L
Labels
Mains Rating, 1-3-5 Warning, 1-3-5 Laser, 1-3-2 aging, 2-1-34 aging control, 2-5-30 alignment, 1-3-4 attenuation, 1-3-4 beam, 1-3-4 enable/disable, 2-1-34 extinction ratio, 2-1-35 manual shutter, 1-3-2 module functional description, 2-5-5 replacement, 3-4-20 radiation, 1-3-3, 1-3-17 replacement commands, 2-1-24 safety Safety, 1-3-2 safety goggles, 1-3-4 service checks, 2-1-32 Temperature and Humdity module, B4 temperature and humidity control, B-4 Temperature and Humidity module, 25-9 temperature and Humidity module replacement, B-5 using test strips, 3-4-31

I
Image
base offset check, 3-1-25 position and skew checks, 3-1-19 set base offset, 3-1-22 set traverse centre, 3-1-21 start position check, 3-1-24 adjustments, 3-4-54 horizontal check, 3-1-16 diagnostic commands, 2-1-52

Image Form

Image Manager

Imaging Engine

Input Module

accessing assemblies, 3-2-27 accessing modules, 2-6-1 Distribution PCBs, 2-3-71 motors, 2-3-75 plate handling, 2-2-7, 3-2-27 plate handling assemblies, 2-3-81 plate handling controls, 2-3-61 plate handling operations, 2-2-19 plate handling sequence, 2-2-26 sensors, 2-3-77 solenoids and relays, 2-3-77 assembly, 2-3-87 description, 2-3-87 removal, 3-2-31 assembly, 2-3-58 functional description, 2-6-6 replacement, 3-5-6

Laser Power Detector Linear Encoder Linear Scale

description, 2-4-10

functional description, 2-5-21 replacement, 3-4-27

Interleaf Diverter and Drive Interlock Box Interlocks

Loading Platform Log Utilities LSB

removal, 3-2-29

functional description, 2-4-11

menu commands, 2-1-19 replacement, 3-5-4, 1-B-1 replacements, B-1 connectors, 2-6-26 functional description, 2-6-26

checking, 3-1-9 DLA external connector, 2-6-16 functional description, 2-6-11 how to override, 3-1-2 protective covers, 1-3-20 safety features, 1-3-19 Inverter, 2-3-11

LSB PCB

Luxel CTP
antistatic precautions, 1-3-24 configuration data files, 2-1-60 introducing, 1-1-2, 1-1-3, 1-1-6, 1-1-7, 11-8

L UXEL P LATESETTER 1-5

Buffer module, 1-1-9 cassette, 1-1-6 drum, 1-1-8 features, 1-1-1 input/output modules, 1-1-8 interleaf bin, 1-1-7 MMI console, 1-1-8 optics base, 1-1-7 plate processor, 1-1-9 plate stacker, 1-1-9 Plate Transport Module, 1-1-7 RFI box, 1-1-8 traverse carriage, 1-1-8 trolley, 1-1-6

Media

schedules, 3-1-4 scanning system, 3-3-1 accessing, 3-4-2 image optical path, 1-2-20 introducing, 1-2-17 Functional Description Spinner Control, 2-4-8 Traverse Initialisation, 2-4-17 operating description, 2-4-7 using, 2-1-70

Media Expose System

Media Scan System

Media Tools Mirror (M2)

Luxel CTP

introducing Autofeeder module Autofeeder, 1-1-5

adjusting, 3-4-54 operation, 2-5-22 Mixer Fan, 2-3-81

M
Main Diagnostics
accessing, 2-1-13 Commands Test Menu, 2-1-27 configuration files updating, 2-1-60 data base service, 2-1-58 Diagnostics menu, 2-1-6 disk service, 2-1-46 EVT menu, 2-1-31, 2-1-32 introducing, 2-1-6 media transport service, 2-1-54 NVRAM, 2-1-21 optics menu, 2-1-32 optics motors service, 2-1-35 optics service, 2-1-32 processor service, 2-1-53 remote menu, 2-1-32 sensors service, 2-1-39 soak tests, 2-1-16 spinner service, 2-1-45 stepper motors service, 2-1-37, 2-1-52 time service, 2-1-43 traverse service, 2-1-43 verbose command, 2-1-15 filter box, 2-6-3 machine pre-requirements, 2-6-2 cleaning, 3-1-5 procedures, 3-1-9 procedures for punch machine, 3-1-17 procedures for Web machine, 3-1-23

MMI

connectors, 2-6-31 console assembly, 2-6-30 Error Codes description, 2-1-10 persistent images, 2-1-9 replacement, 3-2-57 self tests, 2-1-7, 2-1-69 test image output, 2-1-9 touchpanel cleaning, 3-1-5 MMI Setup menu, 2-1-37

Modules Motors
plate handling, 2-2-1 DC tests, 2-1-9 diagnostic commands (step), 2-1-37 elevator (synchronous), 2-2-17 Engine assemblies, 2-3-75 optics replacements, 3-4-16 plate handling DC, 2-2-17 plate handling stepper, 2-2-16 stepper tests, 2-1-8 traverse, 2-4-13

Mains

Maintenance

N
ND_char Neutral Density
running, 2-1-60

1-6 I NDEX

Neutral Density Filter NVRAM

set up characterisation, 3-4-63 setting up characterisation tables, 2-160 setup, 3-4-41 functional description, 2-5-12

PCB
plate handling, 1-2-5

Periscope

functional description, 2-5-20 installing on to HDD, 2-1-67 see Persistent Images, 2-1-9 image form check, 3-1-16 tint checks, 3-1-16 assemblies, 2-3-59 assemblies, 2-3-1, 2-3-51, 2-3-81 Buffer, 2-3-104 common assemblies, 2-2-13 handling sequence, 2-2-21 introducing, 1-2-3 motors description, 2-2-16 operations, 2-2-18 reversing the cassette, 2-2-43 sensors, 2-2-13 accessing assemblies, 3-2-15 contamination control, 2-7-18, 2-7-19 Distribution PCBs, 2-3-43 plate feed controls, 2-3-33 plate handling, 2-2-4 plate handling assemblies, 2-3-4, 2-3-51 plate handling operations, 2-2-18 plate handling sequence, 2-2-22 sensors, 2-3-47 solenoids and relays, 2-3-47 removal, 3-2-30

Persistent Images PIs

configuration files, 2-1-65 diagnostic commands, 2-1-21, 2-1-23 saving/restoring, 2-1-65

Plate

O
Optics
calibration, 3-4-51 diagnostic commands, 2-1-30 introducing, 1-2-17 lens functional description, 2-5-16 light-tight checks, 3-1-13 media expose, 2-5-29 mirrors functional description, 2-5-16 optics_mmi setup menu, 2-1-37 precautionary check, 3-1-11 replacement setups, 3-4-3 selecting macros, 3-4-35 system tests, 2-1-9 test strips, 3-4-31 VBOMB, 2-5-26 modules, 2-5-1 replacements, 3-4-1 Extra Options screen, 3-4-34 Final Values screen, 3-4-33 Machine setup screen, 3-4-34, 3-4-35 tests, 3-4-31 using the menu, 3-4-32

Plate Guides

Plate Handling

Plate Transport Module

Optics Base

Optics MMI

Platen

Optics_MMI Optics_mmi

Position Detector (POD) Post-Failure Analysis

commands, 2-1-26 functional description, 2-5-13 replacement, 3-4-23

Output Module

running test strips, 3-4-37 assembly, 2-3-88 removal, 3-2-32

Power
DC distribution, 2-6-4 DC generation, 2-6-19 inter-module cabling, 2-6-3 service check, 2-1-32 replacement, 3-5-3 connectors, 2-6-21

P
Paper Detect sensor check, 3-1-13 PAT
description, 2-7-21 servicing, 2-7-22

Power balance Power Filter

Power Filter PCB

L UXEL P LATESETTER 1-7

Precautions Processor

functioal description, 2-6-21 antistatic, 1-3-24 exposed components, 1-3-25 diagnostic commands, 2-1-30 interface commands, 1-2-16 See Plate Processor, 1-1-9 system tests, 2-1-9 functional description, 2-6-19 replacement, 3-5-2 adjustments after refitting, 1-B-11 Billows accessing, 3-2-37 adjustments after refitting, 3-2-40, 32-51 assembly, 2-3-93 Centerer checking, 3-2-45 pin checks, 3-2-42 Registration Pins checking, 3-2-44, 3-2-48 Centerer checking, 3-2-49 centering, 3-1-20 Fuji In-house adjustments, 3-2-51 chad wipers, 3-2-54 download text, B-9 removal, 3-2-49 remove motor, 3-2-53 replace punch pins, 3-2-52 replacement, 3-2-51 visual checks, 3-2-52 accessing, 3-2-49

Registration Module Registry

image form on plate, 3-4-54 replacement, 3-2-57 servicing, 2-3-99 see System Registry, 2-1-27 diagnostic commands, 2-1-32 assembly, 2-3-57

Remote Login Retard Pad RFI Box

PSU modules Punch

assemblies/layout, 2-6-16 DC generation, 2-6-19 RFI Filter, 2-3-10

S
Safety
chemical Chemical, 1-3-19 electrical Electrical, 1-3-18 emergency stop, 1-3-22 laser Laser, 1-3-2 mechanical Mechanical, 1-3-18 override key, 1-3-4 signs, 1-3-5 Spinner, 1-3-19 warnings, 1-3-4 designated laser area, 1-3-4

Safety Warnings SaveLog Scanning

using, 2-1-11

Push Bar
assembly, 2-3-91 gear segment replacement, 3-2-36 removal, 3-2-33

SCSI drives

system description, 2-4-7 see Disk Drives, 2-6-29 MMI running, 2-1-69 system tests, 2-1-8 diagnostic commands, 2-1-39 Engine, 2-3-77 inductive, 2-2-16 magnetic reed, 2-2-16 micro-switch, 2-2-16 optical replacements, 3-4-15 opto-reflective, 2-2-13

Self Tests, 2-1-7 Sensors

R
Raster Image Readhead
quality check, 3-4-50 cleaning, 3-1-6 functional description, 2-4-11 replacement, 3-3-11

Registration Checks

1-8 I NDEX

Service Menu Signs

opto-slotted, 2-2-15 PTM, 2-3-47 reflective/diffused, 2-2-16 removal of opto-slotted, 3-2-2 removal of reflective-opto, 3-2-1 vane, 2-3-27 memory, 2-1-31 laser warning, 1-3-5 traverse initialisation, 2-4-17 braking, 1-2-15 control, 1-2-13 description, 2-4-8 diagnostic commands, 2-1-45 functional description, 2-5-23 mirror cleaning, 3-1-5 replacement, 3-3-9 system tests, 2-1-9

Threshold Wedge Tint Checks, 3-1-16 Tools, 1-3-2 Transport Push Bar
see Push Bar, 2-3-91 approved, 1-3-2 setup, 3-4-42

spinner, 2-1-29 traverse, 2-1-29

Software Spinner

Traverse

Spring Shoes Stack Height stacker

replacing, 3-2-34 assembly, 2-3-54

Trolley

accessing, 3-3-2 aligning carriage and ball cage, 3-1-14 cage creep setup, 2-1-26 cleaning scale and readhead, 3-1-6 diagnostic commands, 2-1-29, 2-1-43 fitting the extenders, 3-3-3 functional description, 2-4-10 level check, 3-1-14 motor, 2-4-13 replacement, 3-3-6 PCB, 2-4-5 servo control, 2-4-12 traverse, 2-4-13 traverse carriage assemblies, 3-3-1 assemblies, 2-3-29 docking indicator, 2-3-20

see Plate Stacker, 1-1-9 STB PCB, 2-4-5 connectors, 2-4-5 replacement, 3-3-6

Swing Roller Module

checks, 3-2-56 description, 2-3-100 introduction, 2-3-81 replacements, 3-2-55 see LSB, 2-6-26

U
Umbilical cable Updates
replacement, 3-3-8 revisions to 03, B-1

System PCB

System Registry

displaying, 2-1-64, 2-1-66 tests, 2-1-27 updating, 2-1-63, 2-1-65, 2-1-66 using the utilities, 2-1-63

V
Vacuum System
assemblies, 2-7-4 configurations, 2-7-7 contamination control, 2-7-3 download, B-16 introduction, 2-7-1 connectors, 2-5-26 functional description, 2-5-26 replacement, 3-4-29 setup, 3-4-30

T
Terminal Diagnostics User Interface Tests
entering commands, 2-1-13 menu commands, 2-1-27 optics motors, 2-1-28 processor, 2-1-30

VBOMB

L UXEL P LATESETTER 1-9

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 functional description, 2-5-11

Waveplate

1-10 I NDEX