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Field Service Manual

December 2003

Page 152 of 276

SW860 - MF

Resetting MACCON ...
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| Welcome to M A C C O N |

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Processor Reset, PRID=00000702
Text 0x00000000 Data 0x0000009C BSS 0x00000008 sp = 0xA03FEFF8
Factory configuration .......................
Autoconfig

MACCON BOOT V0.0 Jan 28 1999 09:59:06

Looking for BIST soft ... : found

MACCON BIST V1.1 Jan 26 1999 15:54:19

Press space for interactive mode

CPU test ... PASS
Memory test ... PASS
CON TEMP ... PASS
CON BUZZER ... PASS
CON LED ... PASS
CON SPORT1 ... PASS
CON SPORT2 ... PASS
I/O SPORT ... PASS
IO ADC ... PASS
IO TIMER1 ... PASS
IO TIMER2 ... PASS
IO BAS DUT ... PASS
IO OUT IN ... PASS
DAPO FGS ... PASS
DAPO LEDS ... PASS
DAPO PIXW ... PASS
DAPO SCRWL ... PASS
DAPO SE ... PASS
DAPO HNDSHK ... PASS
DAPO PXVBEAMS ... PASS
DIVI LED ... PASS
DIVI PLL ... PASS
DIVI REG ... PASS
DIVI SE PE ... PASS
DIVI RAM ... PASS
DIVI DIV ... PASS
DIVI LOCK ... PASS

BIST PASSED EnD oF tEsT, bYe
Looking for expose soft ... : found

LTL Rom version M6V12S94.LTL [ Nov 27 2002 ]

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Summary of Contents for SilverWriter 800

Page 1: ...Field Service Manual December 2003 Page 1 of 276 SilverWriter 800 Multi Format Family Laser plotters Field Service Manual December 2003 ...

Page 2: ...rect indirect consequential or incidental damages arising out of the use or inability to use the software or the information contained herein The information contained herein is subject to change without prior notice Revisions may be issued from time to time to advise of such changes and or additions No part of this document may be reproduced stored in a data base or retrieval system or published ...

Page 3: ...ANGUAGE LTL 25 Commands 28 General 28 Carriage 29 Feeder and drum 30 Optic 31 Parameters 33 Pump 35 LASER TOOL LANGUAGE UPDATES 36 FILM FEEDER 37 Adjusting the Film Feeder 37 The Film Feeder Parameter Settings 54 Load process 59 Unload process 68 Vacuumpump 74 The Vacuum Pump Box Components Layout 75 MF Electrical Solid State panel 80 MF Relief valve system 81 SilverWriter MF Valve System 82 MF Si...

Page 4: ...TWARE ON A 32 MBYTE 135 PARAMETER LIST 137 Parameters explanation 137 Editing Exit parameterlist 151 Adjusting parameter values 151 SW860 MF 152 SW830 SF 160 INSTALLATION OF CARRIAGE ON GRANITE 169 Assembling and Mounting of the Base Carriage and linear motor 169 INSTALLATION OF OPTIC ON CARRIAGE 173 OPTICS 600 175 Introduction 177 Electronic boards in the machine rack 180 Theory of the optics 181...

Page 5: ...ip 251 ERROR LIST SILVERWRITER 800 253 Carriage 253 Optic 255 General 257 Feeder Drum 258 Communication 264 Film Job Quality 265 PLOT TIME CALCULATION 269 FILM PROCESSOR CONNECTION 271 INSTALLATION PHASE 273 TOOLS FOR CUSTOMER CARE ENGINEERS 273 SUPPORT 275 Contact information 275 Helpdesk ManiaBarco Asia 276 Helpdesk ManiaBarco Europe Middle East and Africa 276 Helpdesk ManiaBarco North America a...

Page 6: ...Field Service Manual December 2003 Page 6 of 276 ...

Page 7: ...230V input Indication lamp Vacuum tube control signals Ethernet General information Block Diagram Imager Room Green Safe light 230 V PowerRip Data cable Ethernet Vacuum Pump area 3 Phase Power Input Composing area Ucam 230 V Compressor area 230 V 2 x RS 232 2 x RS 232 230 V ...

Page 8: ...Field Service Manual December 2003 Page 8 of 276 ...

Page 9: ... Expose E 2 Test mode LTL After booting Expose L Film sizes Drumspeeds for SW8xx Untill 20320ppi drumspeed 26rev sec 24 beams 20320ppi drumspeed 25rev sec 24 beams 25400ppi drumspeed 20rev sec 24 beams Number of beams SW860 24 beams exposure optic 24 beams SW830 12 beams exposure optic 24 beams SW815 6 beams exposure optic 24 beams ...

Page 10: ... door will open The bridge is first moved up so the cassette is free for film installation The door can also be opened by pressing d and confirming with y at Ready to work In this case the door will open but the feeder bridge will stay down On Button The On button switchs on the vacuum pump This is only needed to load a film manually In standby mode the button appears green Off Button The Off butt...

Page 11: ...lso be seen on the external optional indication lamp In standby mode the button appears dimmed Machine Stop Button The stop button stops the machine at any time It is located on the console at the right hand side of the machine Index LED This LED shows the index position of the drum The color of the LED is green Main On Off Switch This switch is used to switch the main power of the SilverWriter on...

Page 12: ...d Service Manual December 2003 Page 12 of 276 main 220V input and the UPS 220V input are simultaneously switched on off The switch is located on the connector plate on the left backside of the SilverWriter ...

Page 13: ...ervice Manual December 2003 Page 13 of 276 SilverWriter connections All connections power indication lamp pump connections SW communication cables air pressure are located at the right rear side of the machine ...

Page 14: ...Than films are going into unloaddrawer SilverWriter will keep exposing if parameter Unload in drawer B option of parameterlist is on Y If this parameter is on N SilverWriter will stop exposing LED A ON Online up film to unload drawer or film chortly on online detector for developing OFF Online sensor free Film can go to developer LED B OFF Transportermotors not working Blinking Transportermotors w...

Page 15: ...kg load long blades must be available Manual forklift 1500kg must be available during installation The entrance for the plotter and corresponding passageways or corridors must be free from obstacles Is the floor including passageways stable enough Yes No install thick metal plates Does the floor of the plotter room need to be reinforced Yes No Will a film processor be online connected to the plott...

Page 16: ...quate air conditioning must be available and in working order temperature relative humidity airflow Customer has to provide a transceiver box to connect the plotter to his network UTP twisted pair Working telephone connection must be available in the plotter room for service purposes Tables for the plotter PowerRip PC and film box storage must be available Compressed air connection must be availab...

Page 17: ...o be unpacked by the Barco engineer otherwise warranty is void Crate is to be returned If at installation time engineer is on site it appears the site is not completely ready contradictory to what the customer told promised all extra costs lost time return to finish installation will be charged to the customer Remote diagnostics on Plotter 8xx Series All Barco plotters in the 8xx series i e SILVER...

Page 18: ...Field Service Manual December 2003 Page 18 of 276 ...

Page 19: ...Field Service Manual December 2003 Page 19 of 276 Block Diagram Silver Writer Remark Refering also to drawing documents ...

Page 20: ...Field Service Manual December 2003 Page 20 of 276 ...

Page 21: ...cing two Maccons LTL srchidx LTL 22 gpar skipa LTL shinit shopen LTL 4 oneon LTL 4 xxxx sfreq xxxx is freq out of M table for beam 4 LTL 4 600 samp LTL 0 1 adcpot not necessary from maccon 2 5 LTL do rdadc 1e6 wait tilkey put new maccon on same value LTL chrtid On the PCB There must be one jumper installed on JJ3 pin2 and pin3 Closed at the backplane On Pin Header JI2 the linear measuring scale ha...

Page 22: ...b D male 9P 4 6 8 9 C rip field phifac phi_loopback n fr 33 loopctr 50 phi_loopback d num f 27 33 h i l num n r num s t 1 0 INFO d masize num DMA write size in bytes max 3200 INFO f req 27 33 Set test frequency default is 27 MHz INFO h elp Prints this message INFO i nteractive Asks for confirmation after each test INFO l oopctr num Set number of loops default is 5 INFO n oexternal Do only internal...

Page 23: ... SilverWriter The SWIPAN board is used for all the buttons and indicators on the cover from the SW The SWIPAN board is mounted onto the 4 pushbuttons on the cover It is mounted in such a way that the connector J1 is positioned on top Connections to SWIPAN Connector J1 backplane MACBPL J12 Connector J2 filmoff J2 Connector J3 EMERGENCY STOP connections 21 22 Connector J4 Green led indicator Connect...

Page 24: ...Field Service Manual December 2003 Page 24 of 276 ...

Page 25: ...first with the VAR statement name VAR The above statement declares an integer variable with the label name A variable is always set to zero at declaration time But let s take a look at the stack concept When you invoke LTL you get the LTL prompt on the screen This means that LTL has cleared the stack and is ready to accept commands from the keyboard Command execution starts when the key is pressed...

Page 26: ...d You can store the TOS number in a previously declared variable with the name command Example DUP a Duplicates the 1 on the stack and takes one off to store in the variable A TOS 1TOS 1 1 A 0 A 1 Now that we know how to handle integers variables and stack operations the moment has come to start doing something with these numbers A first set of words handles the standard mathematical operations th...

Page 27: ...his is a correct loop construct it will print the numbers 10 up to 1 on the screen 10 DO LOOP This is an error because the word will print the 10 but also removes the loop counter from stack The LOOP word will find nothing on the stack and this will result in a stack empty error 10 DO 1 LOOP This is also incorrect because the word leaves the 1 on the stack the LOOP word will decrease this 1 and en...

Page 28: ...lm on online 6 FEEDET 0 unload drawer closed 7 FEEDET 0 vacuum in suc Caps LTL maccon 1 SIOREL motor feeder bridge on 2 SIOREL direction away bridge 4 SIOREL separation air 8 SIOREL roll down small cilinder 16 SIOREL spare 32 SIOREL spare 64 SIOREL spare 128 SIOREL spare 0 IODET 0 flap end backward 1 IODET 0 spare 2 IODET 0 film against bridge 3 IODET 0 spare 4 IODET 0 spare 5 IODET 0 spare 6 IODE...

Page 29: ... further execution Syntax QUIT Resets the maccon board Syntax HELP LTL HR HELP HRDWINIT Init laser hardware Syntax The commands between the square brackets are processed in batch More than one line can be executed in batch LTL HRDWINIT LTL SRCHIDX LTL while the index is being searched you have the LTL prompt back Carriage Syntax CHRTID After CHRTID the carriage is released because the control algo...

Page 30: ...s 200000000 or 200E6 Syntax 0 SRCHWO PROPAR 0 SRCHWO starts up an automatic routine to determine the offset between the first winding of the linear motor and the glass scale index This procedure should be run whenever the relation between the glass scale and the linear motor windings has been changed e g after replacing a glass scale Syntax x y WINFOR Puts a force y on winding x of the linear moto...

Page 31: ...es potentiometer in feedback loop of I V convertor onMACCON Syntax ALLOFF Switches all the beams off This is used to check for the restlight Syntax ALLON Switches all the beams on Syntax 2000 4000 LOCKRANGE_ALL Gives minimum and maximum locking frequency for all the beams Must be executed and saved during alignment of the optics This takes about 90 seconds Syntax 12 ON ON eats a number from TOS an...

Page 32: ... 5E 2 0 11 89 2663 1491 B 5 52297370 103 100 3 14 0 14 0 11 63 3419 1303 B 6 52289496 134 25 130 4 07 0 18 0 11 68 4004 1439 B 7 52284614 153 63 150 3 72 9E 2 0 11 53 12522 1256 B 8 52279323 174 63 170 4 75 0 12 0 11 88 2826 1494 B 9 52274283 194 63 190 4 74 0 11 0 11 68 3287 1309 B10 52268897 216 210 6 07 7E 2 0 11 68 3316 1538 B11 52263795 236 25 230 6 37 0 12 0 11 98 3735 1350 Diff Pos Differen...

Page 33: ... will prompt you to set y n one or more defaults for options M N T A O par 96 and the lock range LTL defaults is it a drv4x3 Y N y upgrade M table dcdbdv drv4x3 Y N Quality 0 or Speed 1 0 Defaults for RF FREQUENCIES Y N depending on type of machine and base resolution Defaults for beam pin configuration Y N depending on type of machine Defaults for thicknesses and ysizes Y N 7 mil and 4 mil in opt...

Page 34: ...input points 2 CARPOS1 100e6 CORRECTION1 0 DELTA CORRECTION1 1 CARPOS2 300e6 CORRECTION2 45 LTL PROYSIZ Storing parameters Verifying OK LTL Syntax CREYOFFS CREYOFFS will prompt you for input of carriage position correction etc Warning DO NOT START WITH HRDWINIT You will be prompted as follows LTL HRDWINIT LTL CREYOFFS HRDWINIT not allowed Example Creating yoffs table LTL CREYOFFS Number of input p...

Page 35: ...COR Measures and corrects for eccentricity The eccentricity of the shaftencoder must be corrected SECOR calculates this automatically To run SECOR the drum must be spinning LTL secor example of secor on maccon Measuring done SE events stored in trace buffer 0 counts nominal 24414 average 24590 modulus 1487 1ns min 24441 0 6059374 max 24769 0 7279382 Sinus in trcbuf 5 STORE SECOR IN RAM Y N STORE S...

Page 36: ...Service Manual December 2003 Page 36 of 276 Laser Tool Language Updates M6V12S94 Parameter 88 is calculated automatic Secor must be executed at 25 rev s New LTL word DUMPPAR dump all parameters to the screen ...

Page 37: ... SFDREL stepper against belt 8 SFDREL filmfeed bridge up 16 SFDREL air bags up 32 SFDREL transport motors on 64 SFDREL online up 128 SFDREL vacuum ejector on 0 FEEDET 1 roll up 1 FEEDET 0 stepper home 2 FEEDET 0 filmfeed bridge up 3 FEEDET 0 filmfeed bridge down 4 FEEDET 1 film on inline 5 FEEDET 1 film on online 6 FEEDET 0 unload drawer closed 7 FEEDET 0 vacuum in suc Caps ...

Page 38: ... command 1 DRMVAC 2 Check how much vacuum exists in the drum without film The value should be around 70 mbar for a MF with a two valve system If this is not the case adjust the position of the spring inside the first the one where a air pressure pneumatic valve is installed on fisher control valve until you have the correct value To search the high vacuum setting proceed as follows 1 Place a film ...

Page 39: ...ess M and key together LED flashes under With and key you can adjust the value to 7 This is the units digit 7 means mbar Press the M key Led flashes under sw1 With and key you can adjust the value to 2 3 This is the Analog output mode not used Press the M key again LED flashes under sw2 With and key you can adjust the value to 1 This is the type of Operation mode Press the M key during 5 seconds T...

Page 40: ... on Press the M key again LED under flashes on and off With and key you can adjust the value to 10 This is the hysteresis Press the M key again With and key you can adjust the last setting to F 2 Press the M key during 5 seconds The settings are now stored To Zero adjust the sensor Press the and key together and the sensor will be automatically zeroed Sw1 Sw2 ON no vacuum detected vacuum pressure ...

Page 41: ...a 0 or led8 must be out No film in cassette bridge down 128 sfdrel no film must be detected 7 feedet must return a 1 or led8 must be on Model PG30 Refering to Adjustment Model PG30 for Suction caps vacuum Without film 200mbar With film 700mbar Detection 300mbar Hystereris 10 Adjustment Model PG30 for Suction caps vacuum To adjust operation mode Without film 200mbar With film 700mbar Detection 300m...

Page 42: ...1 will switch on Second detection sw2 is not used for suctioncaps Press the M key again LED under flashes on and off With and key you can adjust the value to 10 This is the hysteresis Press M and key together With and key you can adjust the last setting to F 0 Press the M key during 5 seconds The settings are now stored To Zero adjust the sensor Press the and key together and the sensor will be au...

Page 43: ...Field Service Manual December 2003 Page 43 of 276 E 3 Setting conditions are not satisfactory E 4 This error should not appear pressure indication is exceeded ...

Page 44: ...2 The upper speed controller of the rotary actuator controls the speed of the film feed bridge coming down 3 The lower speed controller of the rotary actuator controls the speed of the film feed bridge going upwards Whenever you change the speed of the film feed bridge you have to check it again putting the film feed bridge several times up and down Fine tune if necessary Place the film feed bridg...

Page 45: ...ea Adjusting the air bags 1 Give the following command 16 RFDREL This releases the compressed air in the air bags so that the granite rests on the three bearing balls 2 Check now the height between the upper side of the frame and the bottom of the support plate of the granite The height should be 100 mm You can adapt the height by turning the lower ball bolt When the granit is down be sure that so...

Page 46: ...REL reset the solid state for film feed bridge up LTL 1 RFDREL reset the solid state for the take over cylinder LTL 8 SFDREL Put a film in the cassette LTL 8 RFDREL wait until film bridge is completely down move filmplate to suctioncaps LTL 128 SFDREL LTL 8 SFDREL wait until film bridge is completely up LTL 1 SFDREL LTL 128 RFDREL 5 Now the film should hang by it self without vacuum in the suction...

Page 47: ... the complete film load cassette can change the distance so by adjusting the two feet of the film load cassette 5 The distance between the drum and the suction caps should be around 0 7 cm This is not the reference distance Depending if the film doesn t fall against the drum when he s only holded by the take over the suctionscaps can always be adjusted closer to the drum 6 A reference distance is ...

Page 48: ... 1 and 2 millimeter The unload position Search the value for parameter 42 This parameter brings the drum during unloading into the unload position 1 Bring the yellow roller to the drum 2 sfdrel 2 Move the drum by hand so the spoiler is just before the unload table 3 Ask for the drumposition with the command drmpos where the found value is parameter 42 Vacuum sensor Check the setting of the dual va...

Page 49: ...r raised to get more or less tension in the belt Too much tension causes vibrations insufficient tension causes slip when accelerating or braking causing heat dissipation and noise The motor must be positioned so that the belt can easily be pushed in by 1 cm Adjust the reed switch of the stepper motor when the stepper is in his home position Again this should give a short circuit checking it with ...

Page 50: ...lerloading position 2 sfdrel Adjust the speed and the depth of the roller In the front of the subrack there are several speed controllers The first speed controller top controls the speed of the roll coming down The last speed controller bottom controls the speed of the roll coming up First close them both Switch the compressed air on with the command LTL 1 comsup The command to let the upper roll...

Page 51: ...oller and drum is when the roller is softly touching the drum Be sure to seal the shaft of the cylinder with the nut Check the distance always with compressed air on and performing the commands 8 siorel and 8 riorel several times We now found the rollerunload position Enter the command 0 FEEDET this to check if the detections are working correctly If the result is 1 than the roll is up if it is 0 ...

Page 52: ... Move the cassette as far as possible backwords Away from the filmfeed bridge depending on the spindle motor Use the 1 2 iorel command Install the flap en backward detector in such a way the cassette is detected One can use the 0 iodet command to check the detection Spindle motor ...

Page 53: ...tected On line Online switch on position 1 LTL 5 feedet 1 when unloading the LED is blinking the online bridge is moved up and the film is unloaded in the unloading drawer Online switch on position 2 No LED s are lit LTL 5 feedet 0 no film detected 1 film detected When unloading the LED is blinking the online bridge is down and the film is moved to the developer ...

Page 54: ... to inline Warning Recovering film transport to inline Error EZ Unable to unload can not put film on inline 44 Drum stepper period 750 This parameter can be left to the value of 750 This controls you the speed of the stepper motor during unload and positioning drum during load With this period the fastest speed is obtained with minimal noise The lower the value the higher the stepper motor speed 4...

Page 55: ...elay before the next step in the load procedure is performed It waits until the film hits the drum after the vacuum in the suction caps is gone 53 Wait after blower on ms 2500 This parameter controls the extra wait time after the on signal of the vacuum pump before the next step in the load procedure is performed The reason for this parameter is to ensure that the vacuum level is reached before wi...

Page 56: ... that the end of the film doesn t recoil towards the drum This can be solved by turning the drum in a certain direction expose or counter expose The amount of steps to turn the drum is determined by this parameter Before turning the upper roll is reset After the turning the check on high vacuum is performed 59 Wait after roll down ms 2500 This parameter controls the extra wait time required when t...

Page 57: ...at the vacuum can be released for a certain time without film dropping from the drum For 27 inch the position of the drum is so that the end of the film tail is holded by the yellow roller At that position the beginning of the film spoiler is at the position of the suctioncaps 69 Drum vac release offst from ldpt 3 980 24 25 26 inch This is a very important parameter if you use the option of vacuum...

Page 58: ... 276 70 Film in use in LTL mode 0 9 This parameter is used for testing the filmfeeder in LTL with the correct filmsize Loading a filmsize with the correct parameters Filmsizes around drum 0 1 28 inch 2 3 27 inch 4 5 26 inch 6 7 25 inch 8 9 24 inch ...

Page 59: ...urface of the drum Air pipe Just before the load process compressed air is pumped shortley out of the tube to reduce the sticking of films Bottom plate of load cassette Has four different fixed positions Depending on the filmsize around the drum In inches 24 25 26 27 28 Film bridge This device takes the film out of the load cassette and brings it towards the drum On the film bridge several suction...

Page 60: ...unexposed films As you can see the films are facing the front of the machine and no cover is mounted This means easy for loading films in the cassette Suction caps A low vacuum is applied to several suction caps This ensures that a film can be placed towards the drum ...

Page 61: ...n the suctioncaps touches the first film slightly With the vacuum placed on the suction caps the film is pulled towards the film bridge If there is no film no vacuum can be build and an empty film cassette is generated At the same time the drum rotates slowly towards the load position This position can be changed via a parameter P41 The direction of the drum rotation depends on the start position ...

Page 62: ...p the film bridge The film bridge now rotates by almost 180 degrees During this rotation the position of the suction caps remains unchanged The result of this action is that the film is pulled towards the drum area since the vacuum in the suction caps remains ...

Page 63: ...inder hits the take over plate the vacuum in the suction caps is switched off The film cannot drop because it is sandwiched between the take over plate and the take over cylinder So this means that the film is kept in position by one point Since the position of the take over cylinder is in the middle of the film no movement of the film takes place Now the film is hold in place completely tensionle...

Page 64: ...ield Service Manual December 2003 Page 64 of 276 Drum vacuum After a certain time depending on parameter 52 the low vacuum is now placed in the drum So the beginning of the film is now sucked on the drum ...

Page 65: ...rvice Manual December 2003 Page 65 of 276 Reversing the take over cylinder Due to the low vacuum in the drum area and the beginning of the film being fixed the take over cylinder can return to its home position ...

Page 66: ...itions for film relaxation 24 25 26 inch film edge at spoiler side is holded by the suctioncaps 27 28 inch film edge at spoiler is holded by yellow roller At the end of this cycle the film is puched back to the drum by means of the roller And this in the begin and end position of the film par 61 and par 62 63 64 65 66 of the feeder parameters Par 61 is the drumposition where the rol comes down in ...

Page 67: ...age 67 of 276 Putting the elements in their home position The film bridge is placed downwards Now the film is wrapped around the drum with no tension and the mechanical parts for the load process are in their home positions Film is loaded ...

Page 68: ...ring spinning At every half inch such a hole is made in the drum Just after the mechanical bend of the drum a second row of holes are made in the drum The purpose of this is to firmly attach the film on the drum and to make sure that the film takes the same shape of the drum with no deformation Holes in the drum At the end of the film holes appear in the drum every half inch These holes are connec...

Page 69: ...es towards an unload point You can change the unload point via a parameter P42 in the machine software The drum is rotated at a faster speed then the speed during the load process The rotation can be counter clockwise or clockwise depending on the shortest distance to get the drum into the unload position ...

Page 70: ...rum The roll hits the film with a low force The purpose is to get enough friction between the upper roll and the medium but ensuring that the film is not deformed The unload table leaves a small space between end of table and film You can see on the drawing that the position of the drum is such that the beginning of the film is in the front of the unload table ...

Page 71: ...longer sticks to the drum Because the upper roll is down and hits the film the film is prevented from dropping completely The end of the film drops completely but hits the unload bottom plate The beginning of the film moves upwards due to the stiffness of the film As you can see on the drawing the height of the beginning of the film is higher than the unload table ...

Page 72: ...te As this plate is made from a special material no scratches are made on the surface of the medium As long as the film is kept between the upper roll and the drum the friction force between the transport mechanism and the underside of the film is lower than the friction force made by the upper roll The speed of the film depends on the speed that the drum is spinning From the moment that the film ...

Page 73: ...he transport mechanism the upper roll and the unload table is moved towards their home positions The transport mechanism stops when the film is in the unload tray or over the online sensor Exercice Perform a complete replica of a filmloading and unloading by using the LTL commands LTL words ffload and ffunld are not allowed ...

Page 74: ...ersonnel must be familiar with all the warning signs and precautions laid out in the following operating instructions for the transport installation and operation of this equipment Remark Electrical devices may cause electrical shock Vacuum Pump Siemens 2BH1800 1AK13 Motor Controller 3RW3034 1AB14 Thermal protector 3RV1031 4AA10 Thermal protector 3RV1031 4EA10 Multi pin connector H A3 Pump box con...

Page 75: ...Field Service Manual December 2003 Page 75 of 276 The Vacuum Pump Box Components Layout FIRST LAYOUT ...

Page 76: ...ons of the pump The vacuum pump is used to keep the film on the drum during exposure The vacuum pump unit is a separate unit on 4 roller wheels It must be placed outside the plotter room for reasons of heat dissipation The distance between the SILVERWRITER and the vacuum pump unit must be less than 15meters The vacuum pump unit has the following characteristics Voltage 3 phase 230V 10 25A 50 or 60...

Page 77: ... 380VAC An extra automatic motor fuse for 230VAC is separately supplied with the system This means that for installations where 3 phase 230VAC is supplied the installation engineer will have to do the following on the vacuum pump unit in the relay box replace the 380 460VAC automatic motor fuse with the 230VAC model in the connection box of the vacuum pump motor modify the wiring connection to 230...

Page 78: ...ver during start and stop While running you have a normal relays working Build to drive pumps compressors transport beld Specifications Start time tR on can be adjusted from 0s to 20s we use 5 seconds start time Start voltage can be adjusted from 40 to 100 we use 40 min Stop time tR off can be adjusted from 0s to 20s we use 0 seconds stop time 3 phase Voltages 50 60Hz 200 to 460VAC 10 Power supply...

Page 79: ...V For 230V the 3RV1031 4EA10 is used For 460V the 3RV1031 4AA10 is used Specifications 4AA10 nominal current 16A motor power 7 5kW thermal protection 11 16A Operating temp 20 to 70 C Operating Voltage 690V 50 60Hz Phase error protected 4EA10 nominal current 32A motor power 15kW thermal protection 22 32A Operating temp 20 to 70 C Operating Voltage 690V 50 60Hz Phase error protected ...

Page 80: ...ped REMARK Following command line should be used to move the motor in LTL 1 siorel 5e5 wait 1 riorel No limit protection within LTL Left right movement Motor Film Solid state number 2 SIOREL RIOREL 2 0 motor moves backwards Blow pipe command Solid state number 3 SIOREL RIOREL 4 0 Blower is off Extended position Roller Solid state number 4 SIOREL RIOREL 8 RMF1 Motor direction RMF2 Motor activating ...

Page 81: ...mmand Pressure 1bar is put on the relief valve by means of the pressure regulator what makes them close At that moment the second relief valve takes over and holds the vacuum on about 220 mbar In a single relief valve system you only have to adjust the high vacuum setting Adjusting VACUUM by using the Relief Valve When opening loosening the top part of the relief valve the spring can be seen for a...

Page 82: ...xtra valves added VI valve for switching on the blow pipe 4 SIOREL VJ valve for switching on the Vacuum relief valves commanded by 1 Vacuum command Not used in a single reliefvalve system VK valve for switching forward and backwards the extended position of the Roll 8 SIOREL VK VJ VI ...

Page 83: ... cylinder B440718 The new cylinder is compatible with the old one Only extra distance bushes are used G224200 We have to positions now One just above the drum Controlled by longest cylinder 2sfdrel And one position against the drum 8 SIOREL together with 2 sfdrel Cylinder screws should be fixed aterwards with locktite G22420 B44071 ...

Page 84: ... for Vacuum pump MF REMARK Different fuse is used for 3X220V and 3X460V Fuse B372394 is used for 3X460V also for 3X380V Fuse B372256 is used for 3X230V Soft starter settings Start time 5s Voltage min Speed down 0s FUSE see remark B37239 G2480630 G2480620 G2480632 G2486410 G206770 G2486410 G101710 ...

Page 85: ...ager Loading Filmpositioning cassette Adjust the cassette to the correct filmsize Unloading Filmpositioning unloaddrawer Unload drawer Air inlet Electric connection Main switch Vacuum inlet Film output towards processor Manual film input for processor T ransport control indication ...

Page 86: ...Par 62 Par 3 Par76 84 Chart home pos Defines the origin of the film along the drum for a certain size around the drum Around drum 3 Chart home pos 1 6400 mil 28inch 76 Chart home pos filmt1 1 6400 mil 28inch 77 Chart home pos filmt2 1 6400 mil 27inch 78 Chart home pos filmt2 1 6400 mil 27inch 79 Chart home pos filmt4 1 6400 mil 26inch 80 Chart home pos filmt5 1 6400 mil 26inch 81 Chart home pos fi...

Page 87: ...m ldpt 1 28inch 68 Drum vac release offst from ldpt 2 27inch 69 Drum vac release offst from ldpt 3 24 25 26 inch Par 62 t m 66 Roller position on end of film 62 Back rol pos after flm rel 0 off 63 Back rol pos after flm rel 27 64 Back rol pos after flm rel 26 65 Back rol pos after flm rel 25 66 Back rol pos after flm rel 24 ...

Page 88: ...ting 400 4 00 LTLparameter 70 Film in use in LTL mode 4 12 Film type in use 0 Exposure PowerRip res PR_recorder res 4 Filmsize around drum 0 1 28 inch 2 3 27 inch 4 5 26 inch 6 7 25 inch 8 9 24 inch 00 Filmtypes PowerRip res Adding a filmtype with the correct parameters CONFIGURATION AVAILABLE AND LAST USED confs a26X26 conf_used a26X26 a26X26 film 26X26 marginvtb 0 0 marginhlr 0 0 ressup 4000 800...

Page 89: ...g the correct settings RECORDER EXPOSE SETTINGS AVAILABLE settings 400 RECORDER EXPOSE SETTINGS DESCRIPTION set_n with n from 0 to 15 nominal_ppi num_beams gamma_value spot_oversize sex_range in 10000ths set_400 numset 3 1 2000 24 0 1 9000 11000 2 4000 24 0 1 9000 11000 3 8000 24 0 1 9000 11000 Always do a filmloading and check if the film is correct on the drum ...

Page 90: ... every filmsize changement the cassette has to be adjusted UPLOT OR SMARTPLOT SELECT IN UPLOT THE CORRESPONDING FILM OR IN SMARTPLOT THE CORRESPONDING PLOTTER CONFIGURATION All settings were done in the Plotter parameters Resource files Exercise Filmfeeder setup for three different filmsizes 18x24 22x26 32x28 ...

Page 91: ...Field Service Manual December 2003 Page 91 of 276 Electrical Devices Power panel With MM750 With MM440 ...

Page 92: ...urge protectors installed CF switch elektronic rack 10A CG protection comut el rack CH protection rip not with PowerRip SP From sn105 surge protectors installed CI protection drum motor 3 2A 1 16A 6A 6A 4A 6A 1 16A 6A 6A 1 4A RELAY PKZM 1 16 G195450 RELAY PKZM 1 4 G195454 F AUT 2P C 10A 400V UL R G100741 F AUT 2P C 6A 400V UL R G100781 SURGE PROTECTOR B 370080 Relay PKZM 1 16 Klockner Moeller Rate...

Page 93: ...Field Service Manual December 2003 Page 93 of 276 Film feeder solid state panel Solid state Panels ...

Page 94: ...solid state panel Vacuum pump hi Vacuum pump lo Door down up Comut safety P S Drmon 0 1 drmvac 0 1 vacuum 0 1 flmdoor 0 1 comsup drmon drmoff RLY 60VDC 3A SLST UL RLY I O module G4IDC5D RLY Eight channel mount G1012401 G101300 G101290 Solid state LTL command ...

Page 95: ...Field Service Manual December 2003 Page 95 of 276 Multi FilmFeeder solid state panel ...

Page 96: ...Field Service Manual December 2003 Page 96 of 276 ...

Page 97: ...rameter value remark explanation P001 0 displays the actual frequency into P000 P002 20 acceleration in seconds P003 15 deceleration in seconds P004 0 smoothing in seconds P005 43 frequency setpoint P007 0 enables front panel buttons P009 3 to get access to the next set of parameters P013 60 maximum motor frequency P017 1 smoothing type P018 1 automatic restart after fault P051 turns to the right ...

Page 98: ... memory When P000 is selected and P001 0 the actual frequency is displayed or when the drive is stopped the display flashes the frequency setpoint every 1 5 seconds Do not change P051 to alter the rotation SWAP 2 wires when needed The speed of the drum can be changed when you use the UP or DOWN buttons to change the output frequency in P000 If the acceleration or deceleration of the frequency is t...

Page 99: ...F006 mains phase missing F008 USS protocol timeout F009 under voltage F010 initialization fault F011 internal interface fault F013 program fault F106 parameter fault P006 F106 F112 parameter fault P012 F151 F154 digital input parameter fault When the fault has been corrected the converter can be reset by pressing the button P twice once to display P000 and the second time to reset the fault When 4...

Page 100: ...parameters compared with the old 31 series Also another type of brake resistor is needed Resistor mounted on the frame On the right side of the micromaster The MM440 has a separately front panel BOP Basic Operator Panel that has to be ordered with the MM440 The brake can be mounted on top of the electrical rack Partcode Description B441136 MICROMAS 440 0 75KW 230 1P B441141 MICROMAS 440 B O PANEL ...

Page 101: ...at the preset frequency Release button to stop the inverter Operation of this button can be disabled by P123 0 FORWARD REVERSE button Press to change direction of rotation of the motor Operation of this button can be disabled by P122 0 LED Display P000 P3986 Parameter numbers 000 0 999 9 Parameter values F000 F0924 Fault code Procedure to view or change a MicroMaster parameter 1 Press P display ch...

Page 102: ...tor power P308 rated cos phi P310 rated motor frequency P311 rated motor speed P340 calculation of motor parameters P601 motor temperature sensor P700 selection of command source P701 function of digital input 1 P702 Function of digital input 2 P731 function of digital output 1 P844 BI OFF2 P970 factory reset P010 30 P1000 selection of frequency set point P1001 fixed frequency 1 P1040 set point of...

Page 103: ...ts limit During this process the display flashes as warning Increase the time for acceleration or deceleration to avoid this phenomenon Parameter 964 shows the software version In the event of a failure the converter switches off and an error code appears in the display The last recorded error is stored in parameter number 947 8 Short Error list ERROR description F001 overcurrent F002 overvoltage ...

Page 104: ...e busy sign will shown on the umaster After some time the normal display reappears and you can start using the umaster P1910 is for measuring different motor parameters Parameters Value Comments R001 read only P003 3 3 expert See all params P005 21 21 freq 27 current P010 0 1 quick commissioning P100 0 0 50 Hz operation 2 60 Hz operation USA P300 1 Asynchronous motor P304 230 Volt P305 3 6 Ampere ...

Page 105: ...g current P1233 3 Dc braking time 6seconds P1234 5 Hz moment when dc braking is activated P1237 4 During break 50 is dissipated in Brake resistor P1300 0 P1910 1 Motor calibration should be done once P2106 52 b Diagnostic level P3900 0 3 motor parameters This has to be done to make the parameter changes effective only changeable in quick commissioning mode For RS485 connecting P1000 5 P2000 40 for...

Page 106: ...e Manual December 2003 Page 106 of 276 1 and 2 off RS 485 5 Solide state PSS2 PM18 6 Emergancy stop PM19 PDC21 9 Common line of 5 6 PM17 PDC20 B Brake resistor B Brake resistor 3 phase U V W Input 230V L1 L2 5 6 9 ...

Page 107: ...evious MM connect MM and motor according electrical wiring switch on power We first make a reset of the parameters by putting Parameter 10 30 Parameter 970 1 Adjusting of the motorparameters Put par10 1 Possibility to change the motor parameters p304 to 311 according the parameter list When motorparameters are changed store parameters by changing par 3900 3 Adjust the other parameters to the same ...

Page 108: ...t Remark concerning upgrade kit Code description amount B441136 MICROMAS 440 750W 230 1P 1 B441139 BREAK RES 200E MM440 1 B441141 MICROMAS 440 B O PANEL 1 G115910 SCR D912 M 4 X 12 SS 2 G237181 CBLA CLP D12 7M5 W9 5 ALU 1 G237184 CBLA CLP D 6 4M5 W9 5 ALU 1 G2705470 WIR AM POWER PANEL 1 G2707800 CA RS485 UMASTER BACKPL 1 G2707810 CA AMPHI UMASTER440 PKZM 1 G2707820 AMPHI UMASTER440 MNT PLT 1 V3624...

Page 109: ... of 5 2 electromagnetic EM valves 5 ports 2 states which are commanded via solid state relays The 5 2 valves used are monostable they reset when the power is switched off Safety precautions All EM valves work on 24 V DC Warning Pneumatic devices may only be serviced by Diagnostics and Advanced Service Personnel The following paragraphs contain an overview of the pneumatic parts and their functions...

Page 110: ...lverWriter It consists of the following parts Shutoff Valve Turn the valve 90 degrees clockwise to shut off the compressed air on the manometer the level drops to 0 bar Manometer Pressure Regulator At the main air input 6 10 bar a gauge allows you to adjust the compressed air level to the proper range 5 6 bar Air Filters Water filter Oil filter Air switch valve ...

Page 111: ...h OFF compressed air by turning the valve 1 4 turn to the right Wait until all noise from escaping air has stopped and the manometer reading has dropped to 0 Check status filters Remove filters by turning 1 8 turn to the left bayonet lock Clean filters Remove water and oil if present Put filters back 1 8 turn to the right with bayonet lock Switch on compressed air by turning the valve 1 4 turn to ...

Page 112: ...block surface above the linear motor one vertical air bearing in the center of the bottom part keeping it away from the vertical granite block surface underneath the linear motor Diagnostics on Air Bearings The distance between the carriage magnets and the linear motor surface is about 0 36mm This can be checked as follows cut out two pieces 4x100 cm of thick film 7 mil or 0 18 mm it should be pos...

Page 113: ...he carriage Overflow stop in carriage skip mode high speed Error too large in expose mode ramping at expose speed Remark A sudden drop in compressed air pressure will result in the same errors Such intermittent problem may not be traceable afterwards Air Bearings Manometer Readings Typical factory settings about 5 bar ...

Page 114: ...r labeled AIR BAGS The air is distributed via 6 mm pressure tubes During loading and unloading of films the granite block is down Air Bags diagnostics The EM Valve and the air bags can be checked by the diagnostics commands LTL 16 SFDREL air bags up LTL 16 RFDREL air bags down EM Valve VE can also be operated manually by pressing the button There is a pressure regulator between the switched air ou...

Page 115: ...Field Service Manual December 2003 Page 115 of 276 Never adjust higher than 4 bar Location of air bearings and air bag adjustment Adjustment air bags Adjustment airbearings T O P ...

Page 116: ...s diagnostics The EM Valves and the air jets can be checked by the following diagnostic command LTL 4 SIOREL The EM Valve can also be operated manually by pressing the black button on the valve itself Air speed controls Top speed control is number 1 Bottom speed control is number 8 Upper rol 1 and 8 Take over 3 On line 2 and 7 Extended rol position 4 and 6 In a single format you do not have a exte...

Page 117: ...Field Service Manual December 2003 Page 117 of 276 Upper roll Online Take over Extended roll Extended roll Online up Upper roll 1 2 3 4 6 7 8 ...

Page 118: ...ction line output A vacuum sensor is mounted on top of the Vacuum Ejector The Vacuum Ejector has a permanent compressed air supply and is activated via switched 24 V DC from the solid state relay panel Diagnostics on Vacuum Ejector The Vacuum Ejector is mounted under the compressed air valves Proceed as follows LTL 128 SFDREL A relay switches 24 V to activate the vacuum ejector This ejector can al...

Page 119: ...or a connector is installed You can take the cables out of this connector for easily reversing the polarity The cable can be find on the left side of the stepmotor assembly Short explanation on how the front door motor works The motor itself has two physical stops It are those two physical stops which has to be adjusted so that 1 the motor stops when the door is just closed and detected by the Sil...

Page 120: ...nd chkswi you can verify if the SilverWriter detects the front door when it s closed It s possible that you have to do all this several times untill the door is correct adjusted CHKSWI will read and display the status of 6 switches the status is in normal or reverse video When the switch status changes the display status should toggle filmdoor microswitch of filmdoor Adjusting the upper position c...

Page 121: ...lieved when opening the door Before removing the tube out of its holder don t forget to lock the spring There is a special tool U shaped fork installed on the right side of the motortube which can be used for locking the spring If for one reason the spring has been unwinded it has to be wound up again in the correct direction so it will help the motor when opening the door SilverWriter Correct upp...

Page 122: ...Field Service Manual December 2003 Page 122 of 276 ...

Page 123: ...er Take a note on how the scale rule and head was installed and fixed Install the scale on the same position as the previous one Fix it with the 6 bolts Mount the head and holder at the same position to the carriage as before Adjust the top surface of the measuring head to the same heigth of the top surface of the measuring rule Now fasten the Measuring Head moving part of the measuring rule and m...

Page 124: ...th the 7 bolts M4 x 35 Mount G210460 on G206530 with the 5 bolts M4 x 25 Position G206520 vertically by holding a flat surfacc on face A Press G206520 and the moving part of the measuring rule Measuring Head simultaneously against your flat surface and then fasten G206520 on the carriage In this way both parts of the measuring rule are well aligned Now fasten the Measuring Head moving part of the ...

Page 125: ...een S1 and S2 All signals are available in the LINE DRIVER RS422c STANDARD This means that the inverted signals are also available and that the Treshold Voltages are greater than 0 2 V or smaller than 0 2 V Any difference between the differential signals S1 inverted S1 S2 inverted S2 RI inverted RI greater than 0 2 V or smaller than 0 2 V can then be detected by IC 10 on the L2MRSF Board For Macco...

Page 126: ...mark Do NOT forget to search for a new winding offset par20 after replacing the lineair scale LTL hrdwinit LTL srchidx LTL 0 srchwo propar Check the value of parameter 22 Tune diode pos 1 6400 mil if you have a multi beam Check jobsize in both directions ...

Page 127: ... diameter of the RSF disc 55 0 02 mm Tools Required Measuring gauge max 0 01mm dev for measuring radial excentricity Mounting of the encoder disc 1 Wearing gloves take the encoder disc and slide it gently over the encoder tube of the drum 2 Position the spoiler of the drum so that it faces the laser beam Position the encoder disc so the index face upwards Ensure that the index on the encoder disc ...

Page 128: ...index or encoder steps are located 13 Remove the spacer tool and optical encoder head 14 Turn the drum and align the encoder disc so that the axial eccentricity is within a tolerance of 20 µm 15 Place the dial test indicator radial on the encoder disc and measure the radial eccentricity by turning the drum The tolerance of this eccentricity should be within 50 µm When the eccentricity is larger th...

Page 129: ...re 90 degrees shifted They should be within 80 and 100 degrees shifted phase 4 Connect W_SIDX_N to the A channel 5 Check the index puls signal Note The length of the signal 5µs is drumspeed depending T_SPH1 A T_SPH2 B Ground JB2 Important Remark A logical zero the signal is less than or equal to 0 8 volt A logical one the signal is greater than or equal to 2 volt DO NOT forget to run secor Paramet...

Page 130: ...Field Service Manual December 2003 Page 130 of 276 ...

Page 131: ... From a DOS prompt Start the download program DL EXE 26Kb 18 JAN 96 C DL M6V12S82 b3 B 9600 H you have to stand on the correct directory The H stands for HALT so that after the download is completed the program is not executed immediately but you get a prompt to run or to save the ltl file the filename is just a example DownLoader V1 1 Jan 18 1996 15 49 58 file format Binary or Hexadecimal B H B S...

Page 132: ...eam optics o M Optics 300 600 SSIPRO BMSHFL Multi beam optics o E Elise Optics x Machine identifier x 6 Amphiwriter x 7 BG3700 BG3700M x 8 BG3800 x 9 MegaSetter MegaSetter Plus UL GigaSetter y Ltl main version two numbers e g y 10 ltl version 1 0 z Film feeder version one number t Optic version one number The first LTL versions for all machines will look like Q6V10S11 LTL Q7V10S11 LTL Q8V10S11 LTL...

Page 133: ...dure Switch off power Disconnect the short serial cable between maccon and ssipro Put an extender board in the place of the copy slot of the macbpl left of ssipro Mount second maccon on the extender board Install short serial cable between the two maccons on line 2 After powering up and booting the maccon to LTL mode the LTL word COPYPAR can be used HRDWINIT is not necessary LTL COPYPAR 1 from mas...

Page 134: ...Field Service Manual December 2003 Page 134 of 276 ...

Page 135: ...PowerRip Set Cable port to COM2 COM1 Press a few times Send Sync to check if you have connection with Ssipro After pressing Send Sync you should immediately get the FlashDownload menu again in the normal status If the response takes more than half a second SSIPRO3 is not ready Select the area you want to clear You only clear the area you want to re program Ex From1_1 mcs used in program area Cpudm...

Page 136: ...file menu when you use a Tera Term window Select serial and COM2 Or select call connect on the shortcut keys when you have a Hyperterminal Switch off power and take the Ssipro boards out of the machine Move jumper back from position J27 to position J6 Re install Ssipro connect all cables and powerup the SilverWriter ...

Page 137: ...de of the film Example The following is an example of how to move the left side of the job 5 mm closer to the left side of the film supposing the value of parameter 3 is now 120000000 Calculation of change to parameter 3 5 mm 5000 µm 5000 0 00397 1259446 new value of parameter 3 120000000 1259446 121259446 4 Resolution 4000 defines the resolutions of the plotter Beams in use 24 Beams in use indica...

Page 138: ...00000000 1 32 mil 128 parameter to correct the skewness at position 300e6 10 X expand factor ppm 0 defines the shrink expand factor in the x direction value between 100e3 and 100e3 Value coming from Smartplot 11 Y expand factor ppm 0 defines the shrink expand factor in the Y direction value between 100e3 and 100e3 Value coming from Smartplot 12 Filmtype in use 0 12 types of film settings can be ma...

Page 139: ...set will be automatically calculated in LTL 0 SRCHWO 21 Diagnostic level 512 Defines the amount of information on the screen during initialisation and exposure I table 22 Tune diode position 1 6400 mil 312124832 defines the position of the carriage in front of the diode needed for tuning the beams 23 Machine identifier and enabled options 16844714 defines the options of the SilverWriter Is automat...

Page 140: ...r 27 around drum 73 Vac off time after load 26 ms 7000 Vacuun off after loading for film relaxation for 26 around drum 74 Time out at drawer empty ms 432000000 Time the machine waits after he detected a empty cassette After this time the machine drops out with a cassette empty error message 75 Minimum beams to expose 1 76 Chart home pos filmt1 1 6400 mil 97500000 defines the origin of the film alo...

Page 141: ...origin of the film along the drum for filmt7 setting 7xx For adjustment of this value see explanation at parameter 3 83 Chart home pos filmt8 1 6400 mil 97500000 defines the origin of the film along the drum for filmt8 setting 8xx For adjustment of this value see explanation at parameter 3 84 Chart home pos filmt9 1 6400 mil 97500000 defines the origin of the film along the drum for filmt9 setting...

Page 142: ...he optics is aligned The beam settings frequency and delays for the other resolutions are derived by software from the base resolution settings 96 Drum circumference 1 32 mil 934571 Changing the circonference will corrupt your delay settings The BEAMDELAYS will be retrieved automatically for this new ysize Automatic update of YSIZES according to film thickness done 97 X linear correction ppm 0 def...

Page 143: ...inear correction for a certain filmtype only used for process temperature compensation Linear correction in Y Parameter 98 correction 1000000 1 value l theoretica value measured correction old new Parameter Parameter Parameter 98 98 98 99 SSipro3 enable 100 duty cycle 1 ETSoptics300 600 par 99 1 ...

Page 144: ...am Dpi 2000 Bms 24 Dpi 4000 Bms 24 Dpi 4064 Bms 24 Dpi 8000 Bms 24 Dpi 8128 Bms 24 Dpi 16000 Bms 24 Dpi 20000 Bms 24 Dpi 20320 Bms 24 Dpi Resolutions are coming from the O table BMS Defines the number of beams the optic is adjusted for Multiformat feeder Y or N Unload in drawer Y or N Online switch on II for unloading in developer Y when film stays on top of online sensor SW keeps exposing and wil...

Page 145: ...40 40V Y Mono volt for Comut and Feeder 40V powersupply Auto expose mode N ALWAYS on N Enable drumcor Y or N N if ysiz and yoffs tables are on zero Y if ysiz or yoffs are different from zero Enable secor Y RSF encoder eccentricity correction Goes with LTL command secor Disable skewness N Enable or disable skewness Parameter 8 and 9 Disable shver err Y or N Disabling shutter verify error Shinit eac...

Page 146: ...nal control algorithm for the carriage motion linear motor not to be changed 32 PID P parameter 750 This is the PROPORTIONAL gain of the internal control algorithm for the carriage motion linear motor not to be changed 33 PID I parameter 60 This is the INTEGRAL gain of the internal control algorithm for the carriage motion linear motor not to be changed 34 PID D parameter 3500 This is the DIFFEREN...

Page 147: ... ver 8 0 your choice M By choosing M all frequencies and beam delays are displayed on the screen for a shuffle pattern that is interlaced distance between the beams is always twice the resolution This is the shuffle pattern that is used during exposure The M parameters are independent from the number of beams resolution shrx shry The M parameters are recalculated There are separate Frequency and d...

Page 148: ... the asked resolution The default value for T Cor is 1000 then all the beams will be tuned to the value of par 91 The tuned value for each beam can be changed into steps 0 1 of par 91 V8 0 Your Choice A Amp T Cor Amp T Cor B 0 336 1000 B 1 396 1000 B 2 343 1000 B 3 357 1000 B 20 468 1000 B 21 460 1000 B22 484 1000 B23 450 1000 V8 0 beam Q V8 0 your choice Parameter ver 8 0 your choice O By choosin...

Page 149: ... ver 8 0 your choice I This parameter is intended to be used as a mask for screen information 21 Diagnostics level ______ ______ 577 Diagnostic Info general Y chartcon N carriage N tuning N knife Y user info Y batch s s N frm batch N s rfdrel N FF info N FF debug N RIP debug N CS debug N R D debug N scaler N DRV debug N Parameter ver 8 0 your choice F Filmfeed Parameters See chapter Film Feeder Th...

Page 150: ...e number of beams resolution shrx shry This parameter list is used to change the frequencies and delays during alignment of the optics with the test jobs The C values also include the corrections found during optics calibration Example Parameter ver 8 0 your choice C Fill in the testjob exposure settings 4 Resolution dpi 2000 Beams in use 24 5 Number of beams 24 10 X expand factor ppm 0 11 Y expan...

Page 151: ...d machine params LTL shwpar Allows to show and modify the plotter parameters in the RAM of the Maccon LTL propar Store machine params in eeprom main parameter list P PID parameters carriage F filmfeed parameters B machine configuration I diagnostic level O supported resolution N beam pin configuration A multibeam amplitude tune corrections M freq and delay for base resolution G Drumspeed and Resol...

Page 152: ...ss space for interactive mode CPU test PASS Memory test PASS CON TEMP PASS CON BUZZER PASS CON LED PASS CON SPORT1 PASS CON SPORT2 PASS I O SPORT PASS IO ADC PASS IO TIMER1 PASS IO TIMER2 PASS IO BAS DUT PASS IO OUT IN PASS DAPO FGS PASS DAPO LEDS PASS DAPO PIXW PASS DAPO SCRWL PASS DAPO SE PASS DAPO HNDSHK PASS DAPO PXVBEAMS PASS DIVI LED PASS DIVI PLL PASS DIVI REG PASS DIVI SE PE PASS DIVI RAM ...

Page 153: ...RRECTION 0 1 32 mil 2 CARPOS 400000000 1 6400 mil CORRECTION 0 1 32 mil LTL getyoffs LTL 1 disyoffs Q to quit 1 CARPOS 0 1 6400 mil CORRECTION 0 1 32 mil 2 CARPOS 400000000 1 6400 mil CORRECTION 0 1 32 mil LTL shwpar P PID parameters carriage F filmfeed parameters B machine configuration I diagnostic level O supported resolution N beam pin configuration A multibeam amplitude tune corrections M fre...

Page 154: ... ppi 15000 27 Delayclk freq ppi 60000 28 Horizontal Offset pixels 0 29 Vertical Offset scanlines 0 71 Vac off time after load 28 ms 7000 72 Vac off time after load 27 ms 7000 73 Vac off time after load 26 ms 7000 74 Time out at drawer empty ms 432000000 75 Minimum beams to expose 1 76 Chart home pos filmt1 1 6400 mil 97500000 77 Chart home pos filmt2 1 6400 mil 97500000 78 Chart home pos filmt2 1 ...

Page 155: ...use 24 88 Forced duty cycle pix 0 off 6 91 ADC value for exp Cr Probe 500 Parameter ver 9 0 Your choice 4 4 Resolution dpi 8000 16000 Parameter ver 9 0 Your choice 4 Resolution dpi 16000 Beams in use 24 88 Forced duty cycle pix 0 off 2 91 ADC value for exp Cr Probe 110 Parameter ver 9 0 Your choice 4 4 Resolution dpi 16000 20000 Parameter ver 9 0 Your choice 4 Resolution dpi 20000 Beams in use 24 ...

Page 156: ...220 vac pump 0 2 2 61 Frnt rol pos after flm rel 0 off 401 CR to continue 62 Back rol pos after flm rel 0 off 8184 63 Back rol pos after flm rel 27 7897 64 Back rol pos after flm rel 26 7610 65 Back rol pos after flm rel 25 7532 66 Back rol pos after flm rel 24 7053 67 Wait after loader back multiformat 0 68 Drum vac release offst from ldpt 2 980 69 Drum vac release offst from ldpt 3 980 70 Film i...

Page 157: ...mil thickness 70 FRQ COR DEL FRQ COR DEL B 0 3725 0 1920 B 1 3370 0 1940 B 2 3018 0 1960 B 3 2661 0 1980 B 4 3741 0 1736 B 5 3392 0 1756 B 6 3031 0 1777 B 7 2680 0 1797 B 8 3744 0 1554 B 9 3391 0 1574 B10 3032 0 1594 B11 2681 0 1614 B12 3741 0 1370 B13 3391 0 1390 B14 3027 0 1411 B15 2680 0 1430 B16 3729 0 1190 B17 3373 0 1211 B18 3020 0 1229 B19 2662 0 1249 B20 3717 0 1011 B21 3361 0 1031 B22 300...

Page 158: ... 1 DPI 4000 DRMSPD 26000 N 2 DPI 40640 DRMSP 26000 N 3 DPI 8000 DRMSPD 26000 N 4 DPI 81280 DRMSP 26000 N 5 DPI 160000 DRMSPD 26000 N 6 DPI 20000 DRMSP 25000 N 7 DPI 20320 DRMSPD 25000 Q to quit V9 0 dpi quit Parameter ver 9 0 Your choice a Amp T Cor Amp T Cor B 0 0 1000 B 1 0 1000 B 2 0 1000 B 3 0 1000 B 4 0 1000 B 5 0 1000 B 6 0 1000 B 7 0 1000 B 8 0 1000 B 9 0 1000 B10 0 1000 B11 0 1000 B12 0 10...

Page 159: ...B22 P22 P22 B22 B23 P23 P23 B23 Q to quit V9 0 beam quit Parameter ver 9 0 Your choice e PPI 2000 4000 5080 8000 10160 16000 20000 20320 BEAMS 24 24 24 24 24 24 24 24 POWER 2000 1900 1500 800 550 280 180 180 FDUTY 28 13 10 6 4 2 2 2 O PPI 2000 4000 5080 8000 10160 16000 20000 20320 SPEED 26000 26000 26000 26000 26000 26000 25000 25000 Parameter ver 9 0 Your choice q Ready LTL cfg Machine Configura...

Page 160: ...an 26 1999 15 54 19 _Press space for interactive mode CPU test PASS Memory test PASS CON TEMP PASS CON BUZZER PASS CON LED PASS CON SPORT1 PASS CON SPORT2 PASS I O SPORT PASS IO ADC PASS IO TIMER1 PASS IO TIMER2 PASS IO BAS DUT PASS IO OUT IN PASS DAPO FGS PASS DAPO LEDS PASS DAPO PIXW PASS DAPO SCRWL PASS DAPO SE PASS DAPO HNDSHK PASS DAPO PXVBEAMS PASS DIVI LED PASS DIVI PLL PASS DIVI REG PASS D...

Page 161: ...ting drv4x3 in slot 0 1 done Initing feeder done LTL cfg Machine Configuration LTL Rom version M6V11S11 LTL Machine type 7600 Optics 12 beam base_resol 4000 Shaft encoder RSF Electronics MACCON SSIPRO Driver drv4x3 in slot 0 1 LTL getysiz LTL 1 disysiz Q to quit 1 CARPOS 100000000 1 6400 mil CORRECTION 0 1 32 mil 2 CARPOS 147000000 1 6400 mil CORRECTION 0 1 32 mil 3 CARPOS 150000000 1 6400 mil COR...

Page 162: ... mil 25 CARPOS 254333330 1 6400 mil CORRECTION 23 1 32 mil 26 CARPOS 265000000 1 6400 mil CORRECTION 24 1 32 mil 27 CARPOS 400000000 1 6400 mil CORRECTION 24 1 32 mil LTL getyoffs LTL 1 disyoffs Q to quit 1 CARPOS 0 1 6400 mil CORRECTION 0 1 32 mil 2 CARPOS 400000000 1 6400 mil CORRECTION 0 1 32 mil LTL shwpar Parameter ver 9 0 _ Your choice p 31 PID Gain parameter 12 32 PID P parameter 750 33 PID...

Page 163: ...pro software version 45 90 Minimum flashing period ns 200 91 ADC value for exp Cr Probe 1000 92 Gamma constant 0 93 Obsolete 0 94 Pitch and deltas 0 95 Base resolution 4000 96 Drum circumference 1 32 mil 934600 CR to continue 97 X linear correction ppm 0 98 Y linear correction ppm 0 99 SSipro3 enable 100 duty cycle 1 Parameter ver 9 0 _ Your choice 4 4 Resolution dpi 4000 5080 Parameter ver 9 0 _ ...

Page 164: ...47 Film from drum release time ms 3000 48 Wait before take over ms 1000 49 Wait after take over ms 3000 50 Load drum stepper period 1200 51 Load drum stepper acceleration 600 52 Wait after suction caps off ms 2000 53 Wait after blower on ms 2500 54 Timeout inline to online ms 20000 55 Timeout online to processor ms 30000 56 Push plate before loading ms 0 57 Drum vac release offst from ldpt 40 58 W...

Page 165: ...e 5 70 Ftype 6 40 Ftype 7 40 Ftype 8 40 Ftype 9 40 Ftype 10 40 Ftype 11 40 Q to quit V9 0 Ftype quit Parameter ver 9 0 _ Your choice m Frequency and delay table for 70 or 40 1 10mil thickness 70 FRQ COR DEL FRQ COR DEL B 0 3000 0 2063 B 1 2694 0 2073 B 2 3111 0 1850 B 3 2795 0 1860 B 4 3207 0 1637 B 5 2902 0 1645 B 6 3305 0 1426 B 7 2997 0 1436 B 8 3403 0 1214 B 9 3093 0 1224 B10 3485 0 1006 B11 3...

Page 166: ... 0 _ Your choice a Amp T Cor Amp T Cor B 0 0 1000 B 1 0 1000 B 2 0 1000 B 3 0 1000 B 4 0 1000 B 5 0 1000 B 6 0 1000 B 7 0 1000 B 8 0 1000 B 9 0 1000 B10 0 1000 B11 0 1000 Beam 0 or Pin 1 numbering Parameter ver 9 0 _ Your choice n BNR PNR PNR BNR BNR PNR PNR BNR B 0 P 0 P0 B 0 B 1 P 1 P 1 B 1 B 2 P 2 P2 B 2 B 3 P 3 P 3 B 3 B 4 P 4 P4 B 4 B 5 P 5 P 5 B 5 B 6 P 6 P6 B 6 B 7 P 7 P 7 B 7 B 8 P 8 P8 B ...

Page 167: ...Field Service Manual December 2003 Page 167 of 276 B22 P22 P22 B22 B23 P23 P23 B23 Q to quit V9 0 beam quit Parameter ver 9 0 _ Your choice q Ready ...

Page 168: ......

Page 169: ...on of magnets parts are 1 time S N N S and 2 times S N Mounting the Linear Motor Base Carriage Linear Motor 1 Place the two PVC strips on the vertical weak iron so that the front of these PVC strips are in the same plane as the weak iron 2 Clean the granite and weak iron with aceton 3 Check that the windings of the linear motor are correct This is done by checking if there is no short circuit betw...

Page 170: ...from winding 0 on the magnets This recurs at intervals of 1 inch LTL 0 0 WINFOR To cancel the force in winding 0 Repeat this for each winding The linear motor can be checked for short circuits and open circuits To do so proceed as follows 1 Power down 2 Disconnect the linear motor winding connector 3 Remove the ten straps on the linear motor 4 Measure the resistance of each winding to check that t...

Page 171: ...om the granite surface Loosen air bearings one by one by half a turn and start with the horizontal ones Ensure that the air bearings are not rotating around there screws so that the air pressure tubes are not damaged The carriage is now completely resting on the magnets Adjust the air bearings so that they just touch the granite surface Rotate turn further starting with the vertical ones so that t...

Page 172: ...Field Service Manual December 2003 Page 172 of 276 ...

Page 173: ... carriage Separaters must be on those positions were the screws are installed to fix the optics to the carriage Position the optic in such a way so the right rear corners of optic and carriage are matching Fix the optic baseplate with three screws Install left 1 and right 2 guiding bars For getting a more stable optic baseplate Fixing the screws make them all first handtight Then fix the vertical ...

Page 174: ...Field Service Manual December 2003 Page 174 of 276 ...

Page 175: ...hese operating instructions and all the warning signs attached to the machine Make sure that the warning signs are kept in legible condition and replace missing or damaged signs Before starting familiarize yourself with the equipment Only Advanced Service Personnel may service the optics 300 600 Advanced Service Personnel should be aware of danger from the laser ...

Page 176: ...of the Optics 600 For this a special TRAINING is required USING THE NOTICE BOARD LASER REPAIR IN PROGRESS ANSI Z136 1 During service a temporary laser controlled area may be required Such an area which by its nature will not have the built in protective features as defined for a laser controlled area shall provide all safety requirements for all personnel both within and outside the area A notice ...

Page 177: ...xth seventh and eighth line during the second revolution and so on This is a non interlaced exposure One of the most important drawbacks of this kind of exposure is the fact that some beam overlaps occur simultaneously and others occur subsequently beam 4 of rev n and beam 1 of rev n 1 For some new films Agfastar Kodak Ultratech the delay between the two exposures makes the emulsion behave as if i...

Page 178: ...rriage has moved 12 pixels and the second revolution starts drawing pixel no 12 The distance between the beams would be twice the resolution if you exposed with an odd number of beams perfectly interlaced To expose with an even number of beams the position of the beams or shuffle pattern must be carefully chosen ...

Page 179: ...ty is not correct the machine will adapt the amplification of the RF signal In the parameter list option B you can enable tune each exposing Delay and separations The beam pattern is a tilted 6 x 2 4 raster For exposure the beams have to be delayed independently of each other The Ssipro board gets the correct delay parameters depending on Ysize position of the beams and film thickness and generate...

Page 180: ...sed 24 volt used in multibeam box MONOVOLT SUPPLY PK400 40 VOLT SUPPLY 8 10 Ampere Maccon ADAPTED FOR RSF SCALE ADAPTED FOR BEAM TUNING Generation of the pixel clock I2C interface Correction of shaft encoder eccentricity Ssipro As a consequence of the interlaced exposure principle the expose data coming from the RIP has to be shuffled and delayed before it can be sent to the optics CARLAS Drives t...

Page 181: ... 16 of the laser beam emerges from the bottom coated region and 84 is deviated towards the mirror This beam is reflected 100 by the mirror and emerges from the second coated region on the prism Again a part of the beam is deviated and is reflected by the mirror This is repeated until six beams emerge from splitter The mirror is placed with regard to the splitter prism in such a way that the 6 beam...

Page 182: ...cy of the modulated signals The intensity of the diffracted beams is proportional to the square of the amplitude of the modulated signals These 24 modulated signals are generated in the Multi Beam Box and the signals are adjustable in frequency and amplitude The frequency and amplitude are controlled by the I2C bus The I2C interface is located on the MACCON board The beams pass L3 F83 which is a c...

Page 183: ...delays between the beams they are delayed independently of each other All beams converge in 1 point the telecentric point The doublet The doublet is the focussing lens The optical resolution depends only on the focal length f of the doublet When the TC point is at f distance from the doublet the beams leave the doublet in parallel and are focussed at f after the doublet By moving the doublet the f...

Page 184: ...t customers side are already setup So be carefull using defaults Defaults will set your tables to standard settings LTL defaults is it a drv4x3 Y N y upgrade M table dcdbdv drv4x3 Y N Quality 0 or Speed 1 0 Defaults for RF FREQUENCIES Y N Defaults for beam pin configuration Y N Defaults for thicknesses and ysizes Y N Defaults for DELAYS Y N Defaults for TUCOR Y N Reset knife_corrections Y N Upgrad...

Page 185: ...to be stored before SKYMAX is executed LTL 2000 4000 LOCKRANGE_ALL LTL PROPAR Enable Quadding in parameter list option B Disable optics calibration in parameter list option B and check whether frequency corrections are zero in parameter list option M Set par 13 non retuning range to 10 At the end of the optic adjustment perform a skymax and save the values ...

Page 186: ...Field Service Manual December 2003 Page 186 of 276 Distances amphi F50 F40 1 5mm M1 splitter 40mm M1 AOM 245mm X 15mm 1270 X 76 4mm 2540 X2 130mm 2540 X2 160mm 1270 ...

Page 187: ...Field Service Manual December 2003 Page 187 of 276 ...

Page 188: ...can be made on the wall where the beam points to Remark Laser 05 LHP 151 is a 5 mW polarized laser which needs a power supply 05 LPM 902 065 with an output voltage range of 1850 2450V and current 6 5 mA See ᄬ below Lens L1 Biconvex lens F50mm Insert L1 in its holder as close as possible to the laser Mount it on rods of laser adapter plate no 2 and check if the beam points at the same target on the...

Page 189: ...stment on L1 and L2 is necessary Mirror M1 1 Mount M1 2 Align mirror M1 so that the laser points through the first coating on the splitter If the previous laser was still working and you have aligned the laser through the first and in the second target Than you can go to Splitter Position your target on M2 The lowest beam should be a bit lower than the lowest hole of the 3 holes optical wand and t...

Page 190: ...r it can be that the lowest and the highest beam have a difference in intensity Rotate the laser to make the two beams equal Ex beam 1 top 406 µA beam 2 158 µA beam 3 154 µA beam 4 184 µA beam 5 253 µA beam 6 bottom 400 µA Try to keep top and bottom beam within 5 Mirror M2 Mirror M2 defines the modulator angle 1 Position 3 holes optical wand in front of mirror3 Adjust mirror2 so that all beams are...

Page 191: ...ates in wich direction left or right the beams must be deflected In our optics the deflected beams must be on the right side of the main beams mount AOM so that AOM label is unreadable Align AOM so that the intensity for frequency 3950 is a maximum for the 6 channels Set even beams on frequency 2100 and odd beams on 3900 The intensities for the even beams are about 2 times larger then the odd beam...

Page 192: ...samp Align angle and height of AOM for maximum intensity for deflected beams Connect diode to multimeter and measure intensities of the modulated beams Put two beams at freq 2300 amp 4095 For each beam you should obtain an intensity of at least 10 µA AC Also check if the intensity variation is not too high e g difference in intensity of beams less than 3 µA AC ...

Page 193: ...der blocker assy 2 is important to reduce the rest light After alignment of the order blocker knife position the part where the knife is mounted on G233070 must be fixed with the screws at the left and right sides Mirrors M3 and M4 1 The deflected beams must follow the centered line 2 Position the beams in the center with M3 at position just after M4 3 Position the beams in the center with M4 at p...

Page 194: ...h in both directions x and y Exposure around the drum The drumspeeds are staying the same for the resolutions It means that a pixelclock which is made to switch the beams on in a equal speed changes from freq when another resolution is used Exposure along the drum Depending on the resolution the carriage has a certain speed Ex 4000ppi 1 pixel 25 4mm 4000 0 00635mm 6 35 um So one pixel is 6 35um It...

Page 195: ...er the modulator you could have 6 groups of two beams 12 beam plotter on top of eachother or 6 groups of four beams on top of eachother 24 beam plotter If the beams would go straigth to the drum the position of the beams on the drum would be like this for a 24 beamer and a 12 beamer 24 beam The more beams you have the bigger the distance can be between the first and the last beam After one turn of...

Page 196: ...d in the past A optic for a SilverWriter with TRIP was always adjusted for the number of beams a customer applied for For the first optics with a PowerRip it was the same NOW the optics are always adjusted for 24 beam If the customer has bought only 12 beams the PowerRip software will only allow the plotter to expose with 12 beams In the past with a TRIP with the first multibeam optics this was im...

Page 197: ...tion not correct move M3 and M4 until the position of TC is correct Check if there are any spheres around the spots If you have tails at the spots check if spots go through the center of the doublet and check if TC stop is correct Checking the mechanical stability of the laser path To make sure that all the optical components on the plate are fixed execute a little tap on all the holders of the op...

Page 198: ...x the knife to the diod holder Loctite 330 multi bond kit glue 330 Activator 7386 Set tune diode mount in focus plane Use a gauge to measure the distance between the drum surface at the height of the laser beam and the knife surface The distance between A and B must be about 430 µm 10 µm 180 µm for 7 mil film half thickness of the knife FILM DRUM KNIFE Half tickness of knife 180µm B A Knife positi...

Page 199: ... SKIPA LTL 4 oneon LTL 4 4095 SAMP LTL 4 3000 sfreq LTL 0 1 ADCPOT not necessary from maccon 2 5 LTL SHINIT LTL SHOPEN LTL DO 10000 SKIPR GETREF RDADC 1E5 WAIT TILKEY At a certain position the RDADC value will increase up to a maximum This is the start position of the sensitive area The end position is found when the RDADC value decreases again Store the mid position of the sensitive area in par 2...

Page 200: ...ltmeter Connect the diode to the ADC input on MACCON Then adjust the range of the ADC on MACCON so that the 0 35 µA DC matches the value 2000 LTL rdadc Remark The higher the resolution the lower the laserintensity has to be on the film When high resolutions are used from 16000ppi and higher the ADC on Maccon has to be adjusted to a lower value so it matches with the value 2000 LTL rdadc Otherwise ...

Page 201: ... be kept For finding the correct density on the film we adjust the laserintensity for exposure This is done by parameter 91 of the SilverWriter Out of experience we know that for Kodak film we need a laserintensity of about 0 13uA depending on film and developersettings We will use the samp command in LTL to reach a laserintensity of 0 13uA Measurement is done on the diod with our multimeter conne...

Page 202: ...t this until you have found the right value 5 Tighten up the screws from the doublet 6 Execute SCANK for all the beams LTL 1 1 22 gpar ffffff 1000 SCANK Remark Spot diameter about 7 um for a basic resolution of 4000ppi Angle Abbe König prisma The angle of the Abbe König prism is adapted so that the distance between the position of B0 and B23 is 298 45 um for a basic resolution of 4000 ppi number o...

Page 203: ...r skipa no rest light should be present intensity measured 0 04 µA DC Remark If restlight is bigger then 0 04µA clean optic parts Especially the modulator Clean with aceton Shutter Even when all the beams are switched off there is still some light on the drum restlight The shutter is used to block the laserlight completely Lasebeam position on shutter Shclose position Shopen position Correct laser...

Page 204: ...the laser intensity If there is a to big difference in value you should turn the laser This because of the polarization of the laser to the splitter Mirror2 Position the 3 holes optical wand in front of mirror3 Adjust mirror2 so that all beams are on the correct height The middle of the six beams should be in the middle of the 3 holes optical wand hole Afterwords you adjust all beams about 1mm lef...

Page 205: ...ced_dc 14 pix pixwid 15 pix tune_duty_min 5 pix tune_min_on 114 ns BASE 4000 PPI 4000 POWER 1400 BEAMS MAX 24 USED 24 XLCT 0 YLCT 50 DRUMSPEED 25000 DRUMCIRC 935710 YSIZE 1754544 NOM DELAY CLOCK 60000 BPLCLK 10965899 hz 15000 dpi DELAYCLK 43863599 hz 60000 dpi B P DELAY FREQ DC POS IMAX B P DELAY FREQ DC POS IMAX 0 0 2523 3230 9 0 4095 1 1 2542 2900 9 2 4095 2 12 2562 2567 6 4 4095 3 13 2581 2232 ...

Page 206: ... 311645359 0 0 0 0 5 91 0 204 3230 B 1 318789893 13 07 12 7 0 0 37 7 05 0 1447 2900 B 2 318786565 26 28 25 4 0 0 88 6 79 0 1297 2567 B 3 318783397 38 85 38 1 0 0 75 7 3 0 1158 2232 B20 318728101 258 31 260 35 0 2 04 6 41 0 1505 3330 B21 318724741 271 64 273 05 0 1 41 6 54 0 1631 2981 B22 318721669 283 84 285 75 0 1 91 6 67 0 1479 2637 B23 318718437 296 66 298 45 0 1 79 6 92 0 1556 2294 ...

Page 207: ...lect frequency and delay test 1 Initial offset on freq Increment on freq Initial offset on delay Increment on delay Ini Offset on power 0 Increment on power 0 Duty_test forced duty cycle for 2000ppi depending on delayclk Half of base resolution Ssipro On de iiiiii ctrl c or reset ssipro Select y for rebooting and t for testjobs ppi 2000 beamcount 24 12 filmtype 0 par12 shrx 0 shry 0 mode 0 freq de...

Page 208: ... choice c Fill in the testjob exposure settings 4 Resolution dpi 2000 2000 Beams in use 24 5 Number of beams 24 10 X expand factor ppm 0 11 Y expand factor ppm 0 12 Film type in use 0 Beam or Pin numbering p Fast input Y y Freq or Delay f or d Offset to increment or decrement while using arrow keys up or down 1 ...

Page 209: ...s is the Pin number on position 0 For each beam alignment there are 2 squares first square with combination P0Px second square with combination PxP0 The position of Pxx is correct when the densities of both squares are the same Take into account that 9 frequency steps correspond to approximately 1 um for a basic resolution of 4000 ppi and F20 ...

Page 210: ... with combination PxP0 The position of Pxx is correct when the densities of both squares are the same Take into account that 1 delay step is approximately 0 6 µm The corrections on frequency and delay settings have to be adapted in the parameter list in option C and stored Remark Check for single lines in the delay testjobs Single lines may NOT be present PAR94 is actual the value out of the freq ...

Page 211: ...un if the correct license is installed A license file has to be requested at the office in Gent A request can be sent to license eur maniabarco com The PowerRipPC name and the Host ID is needed to create the license dat file Below you see how to find the requested data Use the ipconfig all command to get the correct info The license dat file has to be installed on the c rip flexlm directory PowerR...

Page 212: ...twork to have a backup of these important files 2 Close all open programs 3 Switch off the plotter 4 Check on Windows NT start settings control panel services Windows 2000 start settings control panel administrative tools services If the following services are still running Barco Phifac it starts up a Hotidle process in the Task manager FlexLM it starts up a barco exe process in the Task manager I...

Page 213: ...anual December 2003 Page 213 of 276 Check in the Processes of the Windows Task Manager if Ripmanager exe is still running If yes first select the Ripmanager exe process and stopt it by selecting the End Process button ...

Page 214: ...rrect Service Pack is installed Open Windows explorer in the toolbar click on the Help menu click About and check the Service Pack it should read Windows NT Version 4 0 Build xxxx Service Pack 6 Windows 2000 Version 5 0 Build xxxx Service Pack 1 If a lower version of Service Pack is installed then first install the above mentioned one Put the PowerRip CD Rom in the CD rom drive Windows NT double c...

Page 215: ...AMCC chip has the number S5935 and NOT S3935 as mentioned in the PowerRip installation process When Earlier than S 39 35 was selected a Barco Phifac service is started and a Hotidle process in the Task manager When S 39 35 or later was selected no extra software is activated for the Phifac board ...

Page 216: ...Field Service Manual December 2003 Page 216 of 276 ...

Page 217: ...a back up the resource files will not be overwritten During a new installation no resource files will be installed and also no c rip rdbg directory will be created c rip rdbg is the resource directory Others Templates of the resource files will be installed on the directory c rip rdbg ᄬ Next ...

Page 218: ...ge 218 of 276 ᄬ Finish The Update Installation has now been completed and the POWERRIP PC will now automatically reboot After the pc is rebooted the POWERRIP is ready to be used Login to the system with Username rip no password is required ...

Page 219: ...is running and the network cable is installed Hotidl should also run again in processes of the Windows Task Manager if Earlier than S3935 AMCC chip was selected during the upgrade installation At the end of Upgrade Installation be sure that Resource files are back installed C rip rdbg powerrip res pr_film res pr_recorder res License file is back installed C rip flexlm license dat Ucam db is back i...

Page 220: ...Field Service Manual December 2003 Page 220 of 276 Main directory structure ...

Page 221: ...Field Service Manual December 2003 Page 221 of 276 Programs started during booting POWERRIP specific files Resource files ...

Page 222: ...e normal log files created for each exposed film and the general log file LogFile log The standard film log files contain all actions performed by the POWERRIP and the plotter in order to expose a film The LogFile log file contains all the processes performed by the POWERRIP ...

Page 223: ... plotter queue This is an ascii file but you should never modify this file The Ripmanager checks the checksum of this file if anything has changed due to manual modification then the JobList txt file is deleted and a new one is automaticly created when a new job is submitted in the plotter queue ...

Page 224: ...his is actually the executable that controls the whole plotting process on the POWERRIP It is one of the programs that is automatically started during booting of the POWERRIP RipUplot exe This program enables you to manually interact with the Ripmanager from out of a DOS window RipUplot options ...

Page 225: ...Field Service Manual December 2003 Page 225 of 276 Adding a DPF file in the plotter queue ...

Page 226: ... the SSIPRO3 board in the plotter RS232 serial cable connected to serial port COM1 of the PowerRip and to the MACCON board in the plotter RS232 serial cable connected to serial port COM2 of the PowerRip and to the SSIPRO3 board in the plotter In order to log events that happen on theses 2 serial lines one can open a log file in the TeraTerm VT terminal emulation program Start logging you will be p...

Page 227: ...Field Service Manual December 2003 Page 227 of 276 Stop logging ...

Page 228: ... 1000 FILMREGISTRATION ON DRUM T C B JOB V REGISTRATION ON FILM T C B JOB H REGISTRATION ON FILM R C L filmreg B jobvreg B jobhreg L BORDER AROUND NEGATIVE JOB 0 WHOLE FILM 1 BORDER OF NEGBORDSIZ MIL negbord 1 negbordsiz 0 CONFIGURATION AVAILABLE AND LAST USED confs KODAK19_5X26 KODAK22_5X26 conf_used KODAK19_5X26 DESCRIPTION OF CONFIGURATIONS FILM TYPE AND SIZE OF FILM SEE FILM RES MARGIN MARGINS...

Page 229: ...p_asym 0 0 0 0 0 0 0 0 ovsp_abs 0 0 0 0 3 3 3 3 jobreg C C negbord 1 negbordsiz 0 pinzone 0 0 setting 400 autoload 2 filmreg C KODAK22_5X26 film 22_5X26 marginvtb 0 0 marginhlr 0 0 ressup 4000 4064 8000 8128 16000 16256 20000 20320 ovsp 1 1 1 1 1 1 1 1 ovsp_asym 0 0 0 0 0 0 0 0 ovsp_abs 0 0 0 0 3 3 3 3 jobreg C C negbord 1 negbordsiz 0 pinzone 0 0 setting 500 autoload 2 filmreg C ...

Page 230: ...Field Service Manual December 2003 Page 230 of 276 Jobreg B L Pinzone B C T L C R maxv maxh sizev sizeh marginvt marginvb marginhl marginhr negbordsiz b ...

Page 231: ... 1 28 inch 2 3 27 inch 4 5 26 inch 6 7 25 inch 8 9 24 inch 00 Filmtypes PR_film res BARCO GRAPHICS Nieuwevaart 153 B9000 Gent Belgium AVAILABLE TYPES OF FILM sizevh size of film in the slow scan direction followed by size of film in fast scan direction type pos for write black neg for write white film name reference name 22_5X26 sizevh 22500 26000 type pos name ARX7 19_5X26 sizevh 19500 26000 ...

Page 232: ...ly automatic 2 both load film optics type of optics 100 or 300 default 100 maxvh maximum size of film v h in mil Note that SSIPRO cannot expose wrong reading AmphiWriter neg 2 wrong 0 skip 1 vcoord 1 hcoord 1 autoload 2 optics 600 maxvh 32000 28000 RECORDER EXPOSE SETTINGS AVAILABLE settings 400 500 RECORDER EXPOSE SETTINGS DESCRIPTION set_n with n from 0 to 15 nominal_ppi num_beams gamma_value sp...

Page 233: ...4 0 1 9000 11000 set_500 numset 10 1 2000 24 0 1 9000 11000 2 2540 24 0 1 9000 11000 3 4000 24 0 1 9000 11000 4 4064 24 0 1 9000 11000 5 8000 24 0 1 9000 11000 6 8128 24 0 1 9000 11000 7 16000 24 0 1 9000 11000 8 16256 24 0 1 9000 11000 9 20000 24 0 1 9000 11000 10 20320 24 0 1 9000 11000 ...

Page 234: ...Field Service Manual December 2003 Page 234 of 276 ...

Page 235: ...xecute the Create_mpr_mf exe file For example from C rip testj Explanation of the Create_mpr_mf exe program The goal of this program is to plot several jobs with different parameters on one film The testjob we will expose on film is called delite dpf A example of the job is found at the end of this testjob explanation You first give in the Number of different resolutions you want on the film Param...

Page 236: ...Field Service Manual December 2003 Page 236 of 276 Selection of the DPF file you want to plot Make MPR files Quit the program or Make more Jobs ...

Page 237: ...EEP AU NOD CONF Agfa fr 33 sh 1000000 1000000 mpr C BARCO BG HARDWARE PRODUCTS RIPS POWERRIP TESTJ 4000w1 mpr licensefile c rip flexlm license dat absosp 0 asymosp 0 prxout C Barco BG HardWare Products Rips PowerRip Testj delite KEEP AU NOD CONF Agfa fr 33 sh 1000000 1000000 mpr C BARCO BG HARDWARE PRODUCTS RIPS POWERRIP TESTJ 4000w2 mpr licensefile c rip flexlm license dat absosp 0 asymosp 0 prxo...

Page 238: ...cted filmtype Execute the bat file and the machine will start exposing if the plotter is initialised Remark When new parameters are found do not forget to change them in the parameterlist or resource files Explanation of parametersettings Index T L Par 6 ADC value for expose 0 mpr paramlist Increment Nr of repetitions Chart home pos 200e6 spoiler 300e6 100e6 ...

Page 239: ...e delite dpf file is created in imperial When making your testplots on a metric resolution you have to check the part of te delite dpf job which is created in metric sizes When making your testplots on a imperial resolution you have to check the part of te delite dpf job which is created in imperial sizes Example of half a delite file ...

Page 240: ...Field Service Manual December 2003 Page 240 of 276 ...

Page 241: ...select the resolution Prpprx Prpprx c rip dpf test Exposing Prxout Prxout c rip dpf test au keep nod conf conf1 absosp 0 asymosp 0 fr 33 sh 1000000 1000000 mpr C rip testj 4000o0 mpr licensefile C rip flexlm license dat switch description default au to select film autoloading manual loading nod elete set the prx delete flag set sh xv yv set the shrink or expand values 1000000 1000000 conf filmtype...

Page 242: ...Field Service Manual December 2003 Page 242 of 276 ...

Page 243: ...p queue using UCAM The queue system is started during the bootsequence At startup the queue is in the STOPPED state and the film type is not set The users can now submit jobs mlf dpf or prx files and interact with the queue through the UCAM system A job in the queue is characterized by its number and has a status priority and film type The priority is a number between 1 and 9 with 1 the highest pr...

Page 244: ...rx files cannot be restarted after succes Some examples ripuplot S will stop the queue ripuplot t will show the queue status ripuplot q will show the queue status reply 155 active filmtype film1 reply 155 Machine stopped reply 155 diskspace 359 Mbyte free reply 154 1 001_07_04_1995 film1 X 7 8000 1000000 1000000 0 reply 154 2 002_07_04_1995 film1 X 7 8000 1000000 1000000 0 reply 154 3 003_07_04_19...

Page 245: ...evious jobs are done p preprocessing mlfdpf d dpf file for different film type D dpf file waiting for dpfprx P preprocessing dpfprx x prx file for different film type X prx file waiting in the recorder queue R Recording S Successfully recorded F Failed check the log file on LOGDIR q deleted while preprocessing mlfdpf Q deleted while preprocessing dpfprx h mlf file Halted G dpf file Halted H prx fi...

Page 246: ...Field Service Manual December 2003 Page 246 of 276 ...

Page 247: ...length of first slow scanline with last slow scanline 2 Parallellogram distortion Parameters 8 9 3 Ysize f carriage position in the corners Ysize table 4 Yoffset f carriage position Yoffs table 5 Ysize f carriage position in the middle Ysize table 6 Making Ysize at 100E6 equal to Xsize Parameter 96 drum circumference 7 Eccentricity correction Secor program which autmomatically calculates the eccen...

Page 248: ...Field Service Manual December 2003 Page 248 of 276 ...

Page 249: ...PowerRip Upgrading the plotter with PowerRip v2 x will make all required modification to allow an UCAM Windows workstation to share a part of the hard disk of the plotter D rip share is automatically made accessible for sharing between Windows workstations this directory is shared with share name ripshare Update Ucam db on UCAM Windows workstation This document contains only the most critical ucam...

Page 250: ... Before sending data to the plotter the layer information and corresponding plot parameters are entered into a merge database Once the information is entered into this database layers can be resent to the plotter without having to be loaded into Ucam again This file is placed local on the Ucam station and must have the extension mdb smartupl mdb_name c plotter smartmerge mdb Test Communication Pow...

Page 251: ...his directory and you should be able to see it from the Ucam Station Extra documents available PowerRip v2 x UcamUnix Trip UcamUnix Trip UcamNT Smartplot Console on PowerRip Update Ucam db on PowerRip Windows workstation smartupl ripdir Example smartupl ripdir powerrip ripshare powerrip is the name of the PowerRip computer smartupl mountdir Example Smartupl mountdir powerrip ripshare powerrip rips...

Page 252: ...Field Service Manual December 2003 Page 252 of 276 ...

Page 253: ...se Solid state ET Check linear motor and cable connections Error Error too large stop on should be Carriage can not go to the position it wants to when moving at expose speed Overflow stop on should be Carriage can not go to the position it wants to when moving at high speed e g after finding the index when making skips while exposing Is something preventing the carriage Check for obstacles Is the...

Page 254: ...ps on linear motor Try replacing linear scale or Maccon Error No ramping Carriage wants to start exposing ramping but for some reason he does not Goes together with no reference counter started ref counter not stopped Maccon LTLversion RSF encoder Error No ramping brake mode 0 Carriage wants to start exposing ramping but for some reason he does not Just before he starts exposing he wants to open t...

Page 255: ...shutter Voltages still present on carlass Connector JF2 Connection 1 2 gnd 17 18 12V 21 22 5V Connector JE1 Connection 1 4 gnd 2 5V shutter cable disconnected Carlass Maccon shutter Cable from electronic rack to carlass Measure cable Groundcable cable electronic rack to carlass connected at carriage and electronic rack Error Tune error EPC Tune error cannot tune beam Unable to switch on a beam Are...

Page 256: ...on shuffle pattern Are the driver boards present during initialising the machine Powersupply driver rack working Led on front is working Check all electrical cable connections for driver rack Circuit braker for laser rack still activated Broken diod cable Is parameter 88 correct Laser or laser powersupply ...

Page 257: ...last divider It s a check on the installed software on Maccon Install latest LTL Error Illegal operation check and reinitialize machine before queueing An error message occurred in the previous job Power off the machine completely and start again Error Maccon goes automatic to Expose Maccon crashes Is going back to expose Check 5V directly on the Maccon board Measure on diod DF1 Main voltages MACC...

Page 258: ...position correct along the drum Film position must be in the middle of the vacuumslits Reposition the complete filmfeeder Films should be flat not curly Sticky films should be separated During loading films can be separated by using parameter 56 of the filmfeed parameters Cleaning drumholes and vacuumslits No long vacuumtube on pumpexhaust Pump environment It should be noted that the temperature s...

Page 259: ... Power Box Stable and correct 3phase input voltage for vacuumpump Vacuum pump PG 30 vacuum sensor Error UNLOAD DRAWER OPEN STOP A unload drawer open has been detected during unloading Check unload drawer lock and his detection Error To many films in cassette Too many films are detected in cassette Flap end backward detector detects the cassette and filmbridge sensor detects films in the cassette I...

Page 260: ...rnt rol pos after flm rel 0 off and Back rol pos after flm rel 0 off Clean drumsurface specially spoiler with aceton Films should be flat not curly Sticky films should be separated During loading films can be separated by using parameter 56 of the filmfeed parameters Cleaning drumholes and vacuumslits Play on filmfeederbridge Filmholder is not going away from films during LTL command 8 sfdrel Posi...

Page 261: ... MM440 If the acceleration of the frequency is too fast the MicroMaster goes into a protective mode for a while and then continues The output frequency is reduced until the current falls below its limit During this process the display flashes as warning Increase the time for acceleration to avoid this phenomenon Parameter 1120 MM750 If the acceleration of the frequency is too fast the MicroMaster ...

Page 262: ...uctioncapsvacuum dropped below suctioncaps vacuum detection Readjust suctioncaps vacuum detection Kavak sensor No film in cassette Put bridge down 8 rfdrel Switch on suctioncaps vacuum 128 sfdrel Adjust kavak sensor untill led 8 on the feeder board is just out PG30 sensor Check vacuum settings values Dammaged suctioncap If vacuum in suctioncaps is not strong enough With new Piab pump with PG30sens...

Page 263: ...ssage Trying to unload film but drum doesn t turn Yellow roller pushes too hard on drum Adjust the roll down small cylinder as short as possible 8 siorel Adjust the roll down cylinder 2 sfdrel so the yellow roller pushes as less as possible on the film Belt tension too low Stepmotor assembly still ok ...

Page 264: ... secor again Phifac ca phifac ssipro Ssipro Maccon Error In log file get_msg errorxx Data error Cyclic Redundancy Check Phifac sends data to Ssiproiii together with a checksum CRC Ssipro receives the data makes also a checksum and compares it with the one from phifac When the two CRC s are not the same you get this message Phifac Ca phifac ssiproiii Ssiproiii Incorrect job Error No heart beat enab...

Page 265: ...ing Check circles or lines plotted in an angle Coax cables at drivers and modulator side are not fixed anymore Laser laser power supply Grey lines Check the beam amplitudes Modulator cable mod drv4x3 drv4x3 Voltage interrupts UPS installed Developer Convertion DPFto PRX Plotted on the wrong resolution Try exposing on a metric and imperial resolution OVSP may not be too big Denisty is maybe just to...

Page 266: ...ncrease parameter 91 to get a higher film density If parameter 91 has reached his maximum value you can always adjust the potentiometer on the maccon board if still possible Blank films Developer still correct Films correct in plotter Emulsion to the front Maccon parameters correct ...

Page 267: ...oper Film accuracy Film may not stay on cold or hot surfaces before or after exposing When plotter room and room with measuring table is not in the same building be sure temperature and humidity is the same and stable When the films are shipped for measuring do not roll up the films but keep them flat If a measuring table is used be sure the table is correct Are the films good Check chapter Testjo...

Page 268: ...Field Service Manual December 2003 Page 268 of 276 ...

Page 269: ...n inch min RESOLUTION ppi NUMBER OF BEAMS X DRUM SPEED rev min X 25 4 mm min RESOLUTION ppi FILMWIDTH inch X RESOLUTION ppi min film NUMBER OF BEAMS X DRUM SPEED rev min FILMWIDTH mm X RESOLUTION ppi min film NUMBER OF BEAMS X DRUM SPEED rev min X 25 4 Number of beams SW12 11 SW24 23 SW815 6 SW830 12 SW860 24 ...

Page 270: ...Field Service Manual December 2003 Page 270 of 276 ...

Page 271: ...t film take up rollers The conveyor bellows connection plate from Barco is fixed to the front of the film processor and fits around the film processor film input slit Wall thickness 10cm 4 max Conveyor top door If the wall is thicker then 10cm the film processor must be installed through the wall Otherwise you will not be able to open the unload drawer pulls out 50cm Close up see underneath Wall F...

Page 272: ...age 272 of 276 Film Processor Input Specification 965 mm 38 905 mm 35 65 50 mm 1 95 900 1050 mm 35 45 41 35 Outher dimension conveyor funnel Maximum size film intake slit Film Processor Height to center of film take up rollers 245 mm 1 95 ...

Page 273: ...racy 0 01mm m for one devision Keep the bubble within 2 devisions Testing the filmfeeder Filmfeed parameter setting Vacuumsettings detections Checking freq and delay Resource files setting Adjusting the filmdensity for each resolution Checking the linewidth for each resolution Accuracy Connection Ucam PowerRip Complete queue of customerjobs Tools for Customer Care Engineers ASS OPTICS300 TOOLKIT G...

Page 274: ...Field Service Manual December 2003 Page 274 of 276 ...

Page 275: ...iabarco com E mail info maniabarco com ManiaBarco GmbH Technologiepark D 61276 Weilrod Germany 49 6083 280 554 49 6083 280 152 ManiaBarco NV Tramstraat 69 B 9052 Gent Belgium 32 9 216 99 11 32 9 216 99 12 ManiaBarco Inc 30 South Satellite Road South Windsor CT 06074 USA 860 291 7000 860 291 7021 ...

Page 276: ...le East and Africa Monday Thursday 09 00 17 00 h Friday 9 00 16 00 h 32 9 216 99 00 General support issues support eur maniabarco com License issues license eur maniabarco com Java HYPERTOOL issues hypertool maniabarco com General information info maniabarco com Helpdesk ManiaBarco North America and Latin America Monday Friday 08 00 AM 8 00 PM PST 1 888 257 2264 General support issues support usa ...

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