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Field Service Manual December 2003
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SilverWriter 800 Multi Format Family
Laser plotters
Field Service Manual
December 2003
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Field Service Manual December 2003
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Copyright
© Copyright 2002 ManiaBarco N.V., Gent, Belgium
All rights reserved. This material, information and instructions for use contained herein are
the property of ManiaBarco N.V. The material, information and instructions are provided on
an AS IS basis without warranty of any kind. There are no warranties granted or extended by
this document. Furthermore ManiaBarco N.V. does not warrant, guarantee or make any
representations regarding the use, or the results of the use of the software or the information
contained herein. ManiaBarco N.V. shall not be liable for any direct, 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, in any form or in any way, electronically, mechanically, by print, photoprint,
microfilm or any other means without prior written permission from ManiaBarco N.V.
This document supersedes all previous dated versions.
Trademarks
All product names cited are trademarks or registered trademarks of their respective owners.
Correspondence regarding this publication should be forwarded to:
ManiaBarco
Tramstraat 69
B-9052 Gent
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Table of Contents
TABLE OF CONTENTS........................................................................................................ 3
GENERAL INFORMATION - BLOCK DIAGRAM
................................................. 7
GENERAL INFO SW8XX ..................................................................................................... 9
Machine mode....................................................................................................................... 9
Film sizes .............................................................................................................................. 9
Drumspeeds for SW8xx........................................................................................................9
Number of beams..................................................................................................................9
Operator switches................................................................................................................ 10
SilverWriter connections..................................................................................................... 13
Online switch ...................................................................................................................... 14
SILVERWRITER MF SITE PREPARATION CHE CKLIST
.............................. 15
BLOCK DIAGRAM SILVER WRITER
..................................................................... 19
DESCRIPTION OF THE BOARDS + ADJUSTMENTS
..................................... 21
THE LASER TOOL LANGUAGE : 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 SilverWriter SUPPORT ROLLER............................................................................... 83
SilverWriter MF Pump CONTR box.................................................................................. 84
Filmsize adjustment on MFF ..............................................................................................85
ELECTRICAL DEVICES
................................................................................................. 91
Power panel......................................................................................................................... 91
Circuit breakers................................................................................................................... 92
Solid state Panels.................................................................................................................93
Drum Micro Master Parameter Table MM750.................................................................. 97
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Drum Micro Master Parameter Table MM440 0.75KW................................................. 100
DESCRIPTION OF THE PNEUMATICS
............................................................... 109
Shutoff Valve.................................................................................................................... 110
Manometer & Pressure Regulator..................................................................................... 110
Air Filters.......................................................................................................................... 110
Carriage Air Bearings....................................................................................................... 112
Air Bags ............................................................................................................................ 114
Blowpipe........................................................................................................................... 116
Air speed controls............................................................................................................. 116
Suction Caps & Vacuum Ejector...................................................................................... 118
FRONT DOOR ADJUSTMENT
.................................................................................. 119
INSTALLATION OF LINEAIR SCALE
.................................................................. 123
INSTALLATION OF RSF ENCODER
..................................................................... 127
DOWNLOADING LTL SOFTWARE INTO MACCO N
...................................... 131
COPYING PARAMETERS BETWEEN TWO MACCON’S
............................... 133
HOW TO DOWNLOAD SSIPRO SOFTWARE (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
Adjustment procedure Optics 600..................................................................................... 184
Alignment of the laser path............................................................................................... 188
Brief explanation of the laser path adjustment.................................................................. 204
TESTJOBS – FREQ AND DELAY
............................................................................ 207
POWERRIP
...................................................................................................................... 211
License file........................................................................................................................ 211
How to update-Install to PowerRip version 2.04 or higher............................................... 212
Resource files.................................................................................................................... 228
TESTJOBS - DENSITY AND LINEWIDTH
........................................................ 235
EXPOSE COMMANDS
.................................................................................................. 241
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MANUALLY SUBMITTING JOBS IN THE POWERRIP PLO T QUEUE
.. 243
TESTJOBS - FILM3&4 GEOMETRIC ACCURACY CHECK
.......................... 247
UCAM - SMARTPLOT INSTALL CONFIGURATION
...................................... 249
Smartplot Console on PowerRip....................................................................................... 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 and Latin America
......................... 276
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Compressed air tube
2 x 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
2
30 V
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General info SW8xx
Machine mode
1. Expose mode (customer operating mode)
After booting : 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)
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Operator switches
Door Button.
The door button is used to open or to close the front door (i.e. a rolling-shutter). This
is needed to access the film cassette and drum area.
Ones the door button is pressed first the filmfeeder bridge will move up and second
the 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 button switchs the vacuum pump off e.g. after exposing with manual
load. In standby mode the button appears green.
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Status Lamp.
This lamp has two functions:
· Continues light: drum is spinning.
· Flashing light : No film in machine.
A severe error has occurred.
This same function can also 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 or off. The
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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.
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SilverWriter connections
All connections ‘power-indication lamp-pump connections-
SW communication
cables-air pressure’ are located at the right rear side of the machine.
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Online switch
B
A
Switch I : Unloading into drawer
II : Unloading to developer – except when developer doesn’t accept
films(film stays on top of onlinedetector). 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 working
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SilverWriter MF Site Preparation Checklist
Customer code:
Plotter type:
Customer contact 1:…………………….. Function: ……………………………...
Customer contact 2:…………………….. Function: ………………………………
Customer contact 3: …………………….. Function: ………………………………...
Customer contact 4: …………………….. Function: ………………………………
Installation address:
……………………………………………………………………………………..
……………………………………………………………………………………..
…………………………………………………………………………………..
………………………………………………………………………………………..
Plotter size: width=1725mm, depth=2358mm, min depth=1500mm, height=1825mm, service
height=2480mm, weight=1500 kg
Crate size:
width=2010mm, depth=2766mm, height=2079mm, 500 kg (2000 kg with plotter)
Has the customer received the pre-installation manual? Yes No
Does the customer have a storing place for the crate? Yes No If
no, plastic must be available to cover the crate
Forklift truck to unload plotter from truck (2000kg 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 plotter? Yes No
The plotter room must be big enough (+1.5m space at drawer side, +1m
space at front and right side, 2.5m height)
Vibrations must comply with specs, in case of doubt contact specialized
company
Vacuum pump box must be installed in a dry and clean area (max temp 30°C)
outside the plotter room. 75dB , 2.7kW at 250mbar , 50
°C
Vacuum tube length to plotter → maximum 15m, ou te r ∅ = 72mm
minimum (supplied by Barco)
Vacuum pump box command cable connector ∅ = 35mm (supplied by
Barco)
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Power cable 230VAC 3phase 25A 6 mm² (protected with 32A very
slow fuse) to the vacuum pump
or Power cable 380VAC 3phase 12A 4 mm² (protected with 25A very
slow fuse) to the vacuum pump
Install transfo if the required Voltages are not available(ex.:from 207V -> 230V)
Customer should provide an UPS for the plotter,will one be available? Yes No
Two 230VAC outlets (1 x UPS 1kW and 1 x 6A) must be available at back left of
plotter
Two 230VAC outlets (1xUPS 500W)must be available for the plotter PowerRip PC
Ground (earth) of power outlets must be interconnected!
At least two 230VAC outlets (UPS 100W) must be available for maintenance
(oscilloscope, lamp,…)
Status lamp (red) mounted against wall of yellow room (230 VAC, light bulb 100
W max) (optional)
Plott er room must be equipped with correct fittings for green safety lamps
(lamp tubes supplied by
Barco)
Tube cyan T20-60cm (x4)
Tube cyan T20-120cm (x2)
Tube cyan T20-150cm (x2)
Plotter room must be equipped with sufficient number of white light fittings
Adequate 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 available. 6-10 bar , 2500 l/h
Compressed air filter (water/oil, dust) must be installed on the wall in the plotter
room (0.01mg/m³, 3µm max)
The film processor must be flat on the front towards the conveyor side
Height and distance to first take up roller
Correct chemicals must be available at start of installation
Film processor (installed through the wall) must be ready to work at
start of installation
Films of the right type and size must be available at start of installation
A workstation complying to the Ucam specs with the Ucam/Smartplot software
installed must be available
Does the customer have a densitometer D>5 (is must for AGFA RL7&STD,
KODAK)?
Yes No
Does the customer have a measuring table / tool? Yes No
Light table of correct film size must be available
Does the customer want installation material before the installation? Yes No
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1 x vacuum hose 15 m length, outer ∅ = 72mm mini mu m
1 x power cable vacuum pump box, cable ∅=16mm, connector ∅=35mm (male
connector at plotter side)
1 x quick acting coupler female part, ¼ F
1 x conveyor connection plate to film processor
Type of film processor Brand: Flat front? Yes No(supplier must adapt it)
Model: Production year:
Type of film Brand: Type:
Size:
(plot size = film size - max 0.1” at left/right/bottom and 0.8” at top)
Plotter room must be completely finished before the installation starts
(requirements see above); plotter is to 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. SILVERWRITER 8XX, BG 748xx, BG
758xx and BG 768xx) are delivered with a modem. When ordering, be sure
the customer’s choice is indicated: either the
analog modem (code 966208)
or
ISDN modem (code966209).
REMARKS:
Enough space around machine ? Also to open drawer ? ……………………………
Be sure that the film can go through the developer !
…………………………………………………………………………………
…………………………………………………………………………………
…………………………………………………………………………………
…………………………………………………………………………………
……………………………………………………
Date: Date:
Name customer (capitals): Name field engineer:
Signature: Signature:
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Block Diagram Silver Writer
Remark: Refering also to drawing documents
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Description of the boards + adjustments
•
MACBPL:
Backplane Maccon
•
Power supplies:
-PK230: Philips PE4136/01
-PK400(comut) 40 V
•
COMUT:
Linear motor windings commutation
-Resistance RB32 cutting if comut is Version 6
•
FEEDER:
Film loading subsystem
-Adjustment of MOT1(150mV)
-Jumper positions.All jumpers installed except 5 and 6 for V4.x
-Jumper positions.All jumpers installed except 3 and 4 for V5.x
•
MACCON:
Machine controler
-Linear motor & solid state relays control
-Clock subsystem and shaft encoder
Freq: Maccon [freq,ampl] I²C
-Software + parameters
-PB1
PB1 →
Adjustment procedure for replacing two Macc ons.
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 ne cessary from maccon 2.5
LTL > do rdadc . 1e6 w ait 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 have to be connected.
• Pin Header JH4 are used for testpins.
• Potentiometer PB1 is used for the ADC. (LTL> 0 [0][1] ADCPOT)
Potentiometer PB2 is spare. (LTL> 1 [0][1] ADCPOT) It can be used for
future development.
• The 512KB flash memory fits in an IC-socket.It contains the boot ROM
code and the machine parameters.
• The 2MB flash memory contains the BIST software and the LTL software.
• One row are the even pins, the other road are the odd pins.
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•
SSIPRO:
Serial sequencial input Parallel rotated output
-Delay: Ssipro [Bn,pos,delay] data
-Software
•
PHIFAC :
In PowerRip
(PCI board, f=33Mhz) (Pci Hotlink InterFace
ACcelerator)
-Cable:Ssipro-Phifac about 7,5m/outside plotter 5m.( Hotlink
Cable(275mbits/s)) High speed serial cable.
-Loopbacktest on phifac. Loopbackconnector:
Sub-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 loopback tests
INFO: /r[eadsize]=num DMA read size (in bytes,
max=dmasize)
INFO: /s[tatus] Print out status after each test
INFO: /t[race]=-1|0 Set trace level (default is -1)
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•
CARLASS:
Shutter control
•
DRV4x3:
Driver boards.
Beam control.Frequence and beam-amplitude.
-
LTL>2000 4000 Lockrange_all
Minimum range : 2060 Maximum range : 3940
FLMOFF: Interlock – Swipan connectie
SWIPAN: Used for all buttons and indicators on the cover of the 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
Connector J5 not used
Philips
PE 4136/01
A556985
PK400
G220441
MACCON
COPYSLOT
SSIPRO
TESTSLOT
COMUT
FEEDER
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The Laser Tool Language : LTL
LTL is a language used to debug the laser machines. LTL is a stack-oriented
programming language, the operators of LTL are called "words" and the variables the
words operate on are transferred via a stack mechanism. LTL-words can operate on
integer constants, integer variables and string constants.
LTL-words can be combined to form single line programs, or when the built-in editor
is used, complete programs can be written. LTL supports also in-line editing, and it
remembers several former command lines. These can be revoked by using the up and
down arrow keys, changing the line, if necessary, and pressing the ‘<>’ key. LTL
input strokes are always converted to upper case before the execution starts.
LTL does not allow the creation of new words, that is combining the existing words
into a new user-defined word.
An integer constant is represented by its string representation; this can also be in
exponential notation: 123400 or 1234e2. A string constant is any alphanumeric string
between quotes: "ON", "OFF", " ". A variable must be declared 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.
The stack itself is a data array with an execution-dependent size. A number or
constant that is moved to the stack is always pushed on the Top Of Stack, variables
can only be removed from TOS. When you put two or more variables on the stack, the
number that is entered last is on the TOS position, the former on TOS-1, and so on.
Constants are pushed on the stack by simply typing the number, variables are pushed
on the stack by typing their label (variable name).
Example
"a" var 1 2 a <>
Creates a variable "a", initializes "a" to zero and pushes 1, 2, and the value of "a",
which is zero, on the stack. After this operation the stack looks like this:
TOS: 0
2
1
The number on the TOS can be removed from the stack by using the DROP word,
swapping the numbers on TOS and TOS-1 can be done by using the SWAP word.
Example
drop swap <>
Drops the 0 from the stack and swaps the 2 with the 1, the stack now looks like this:
TOS: 1
2
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In LTL, the contents of the stack cannot be seen, you can only visualize the TOSnumber. To do this, two words are available: the ?-word and the .-word. The ?-word
prints the number in TOS on the screen and leaves the stack intact; the .-word prints
the number and drops it too. This means that the .-word is a shorthand notation for a ?
DROP command.
Example
? swap . <>
This line will print the numbers 1 and 2 on the screen, and leave only the 1 on the
stack.
TOS: 1
Most of the LTL-words eat a number from the stack(Other LTL-words
put a number on the stack); to keep the number on TOS for later use, the DUP
(duplicate) word is available. To completely clear the stack the CLRSTCK (clear
stack) word is used. 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: 1 TOS: 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: they are the +, -, *, /, % (modulo)
functions. These operators take two numbers from the stack, perform the function and
push the result on the stack. Keep in mind that LTL computes with integer numbers
only.
Examples (start from an empty stack)
64 55 - . <>
This sequence pushes 64 and 55 on the stack, the - word pops 55 and subtracts it from
64 (the 64 is popped too) and pushes the result (9) back on the stack. The .-word
prints the result on the screen and empties the stack.
Now try to find out these:
1e2 34 + . <> ----> 134
12 20 * . <> ----> 240
56 5 / . <> ----> 11
56 5 % . <> ----> 1
2 3 4 + * . <> ----> 14
208 13 8 * ? / . <> ----> 1042
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208 13 8 / ? / . <> ----> 1208
In addition to these arithmetic operators, the following logical operations are possible:
>, >=, < =, ==, < >. These words also pop two numbers from the stack and push a
zero if the logical operation gives a FALSE result, and push a one if the result is
TRUE.
Examples
3 4 == . ---> 0
3 4 > . ---> 0
3 4 <= . ---> 1
3 2 + 5 == . ---> 1
LTL also knows loop constructs:
number DO .... LOOP
DO ...... WHILE
DO ...... UNTIL
DO ...... TILKEY
The LOOP word decreases the number on TOS and goes on with the word after the
DO word if the TOS is not zero. If TOS is zero the words after LOOP are executed. It
is important that the words between DO and LOOP do not leave any supplementary
data on the stack because this disturbs the loop counter.
Examples
10 DO ? LOOP
This 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 end the loop.
The WHILE word repeats the instructions between DO and WHILE if the number on
the stack does not equal zero. If the TOS-number is zero, the loop stops.
The UNTIL word repeats the loop until the number on the stack is not equal to zero.
Both WHILE and UNTIL words usually follow after a logical operation.
DO (commands) TILKEY allows repeated execution of commands put between the
words, until a key is pressed. This sets a "flag", which will cause the loop to be exited
after completion of the commands, so this may take some time!
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Commands
General
LTL >?feeder
1 SFDREL : take over cylinder forward
2 SFDREL : roll down
4 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
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 IODET . : 0 ---> spare
7 IODET . : 0 ---> spare
8 IODET . : 0 ---> spare
• Syntax: CFG
By entering CFG, you get an overview of the machine configuration. The LTL
software version is mentioned, and the installed hardware options for film feed
and circuit boards.
• Syntax: CHKSWI
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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.
· vacon: low vacuum detector
· vachi: high vacuum detector
· filmdoor: microswitch of filmdoor
· stop: stop button on operator panel and emergency stop button.
· start: start button on operator panel
· blower: blower off button on operator panel
• Syntax: 1 COMSUP
COMSUP eats a value (1/0) from TOS and turns the Monovolt Supply on/off
(40 V). And turns the air on/off.
• Syntax: HRDWINIT
Initializes the machine hardware
• Syntax: SCALER
Depending on the resolution, the available beams, SKYMAX
results,shrx,shry and filmtype, SCALER ' chooses another shuffle pattern
• Syntax: 1E6 WAIT
Eats TOS and uses this value as the number of microseconds (0.000001 sec) to
wait before any 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 algorithm is
deactivated, allowing manual motion.
Execute CHRTID before SRCHIDX to make sure the Reference Counter is
cleared from a previous setting by a SKIPA command.
• Syntax: GETPOS .
Reads the contents of the Absolute Position Counter (APC) and puts this value
on TOS. The unit of the APC is 1/6400 mil or 4 nm (nanometer).
• Syntax: 25E6 SKIPR -25E6 SKIPR
SKIPR eats TOS and skips the carriage over this distance, which should be
expressed in glass scale units: 1/6400 mil or 4 nm.
1E6 is equal to 156 mil or 4 mm.
Negative values are accepted (skip to the low end over the glass scale).
• Syntax: 120E6 SKIPA
SKIPA eats TOS and skips the carriage to this absolute position.
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• Syntax: 10E3 1 RAMP
RAMP eats 2 values from TOS:
· The first value is the duration in ms.
· The second value is the direction: >0 is normal expose direction from the low
to the high end of the glass scale. Use 1 or -1.
RAMP will cause a controlled slow speed motion at expose speed. The
command needs some other presettings to prepare for this diagnostic "expose
speed motion": resolution, number of beams, shaft encoder simulation.
Example :
LTL > HRDWINIT SRCHIDX
LTL > 24 NBEAMS
LTL > 4000 RESOL
LTL > 1 SIMENC
LTL > 4E3 1 RAMP ;4 seconds ramping
• Syntax: SRCHIDX
SRCHIDX initializes the glass scale. The linear motor will drive the carriage
in an "uncontrolled" way: current is switched per 2 windings (200 mil). When
the index pattern is detected in the middle of the glass scale, the position will
be taken as 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 motor.
Limits: · force: 0 < y < 255 ➭
use 155 !!!!!!!
· winding: 0 < x < 9
Important
Do not forget to turn off the force: 0 0 WINFOR
Feeder and drum
• Syntax: DRMON
Turns on the drum motor. Use DRMOFF to stop the drum.
• Syntax: DRMPOS .
DRMPOS puts the drum position on TOS.
• Syntax: 0 1 FDPOW
FDPOW eats two values from TOS:
The first value is the stepper motor number: default is 0, since there is only
one stepper motor in use.
The second value stands for the on/off condition:
1 to switch the power on
0 to switch the power off
• Syntax: FFLOAD
FFLOAD will start a complete automatic film load cycle.
• Syntax: FFUNLD
FFUNLD performs a complete unload cycle.
• Syntax: x FLMDOOR
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FLMDOOR eats a value (x=0/1) from TOS.
0 flmdoor = close door
1 flmdoor = open door
• Syntax: ML
Moves the drum to loadpoint.
• Syntax: MU
Moves the drum to unloadpoint.
• Syntax: nnnn ROTA
ROTA eats TOS and stepper motor moves drum over nnnn qenc steps from
index (Absolute)
• Syntax: nnnn ROTR
ROTR eats TOS and stepper motor moves drum over nnnn qenc steps
(Relative): · in expose direction when TOS is positive.
· in counter expose direction when TOS is negative.
• Syntax: RPKS .
Pushes drum speed on TOS. Use the . to display TOS.
• Syntax: MBS
Move bridge sensor.
• Syntax: MFS
Move film stop.
Optic
• Syntax:X Y ADCPOT ; X:pot1=0 pot2=1 Y: off=0 on=1
ADCPOT reads TOS. When TOS = 1, the commmand places 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 and switches this beam number on.
• Syntax: 12 ONEON
Switches all beams off, except the beam number on TOS.
• Syntax: RDADC .
RDADC puts a value between 0 and 4095 on TOS. This command is only to
be used when a Photodiode is connected to the 12-bit ADC Current Probe
input connector of the Maccon board.
• Syntax: 4 2000 SAMP
SAMP eats two numbers from TOS:
· the first number is the beam
· the second number is the amplitude
Set all beams on maximum amplitude:
LTL > 24 do dup 1 – 4095 samp loop
• Syntax: -1 1 22 GPAR $FFF 1000 SCANK
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SCANK 'gives information about pulsewidth and separation between the beams
Knife has to be mounted at a correct distance from drum!
knifedir : -1 carposition decrements while scanning beam
1 carpostion increments while scanning beam
mode : 0 searches beam position
1 searches beam position and beam width
knifepos : par 22
Beam_mask : hexadecimal number of the beams
beam 11 10 9 8 7 6 5 4 3 2 1 0
$1 0 0 0 0 0 0 0 0 0 0 0 1 beam 0
$401 0 1 0 0 0 0 0 0 0 0 0 1 beam 0 and 10
$FFF 1 1 1 1 1 1 1 1 1 1 1 1 beam 0 to 11
imax : adcvalue 0->4095
example of screen output (for beammask $fff)
Beam Rulepos Diff.Pos Soll Cor delta Width Was Amp Freq
(1/6400 mil) (mu) (mu) (mu) (mu) (mu) (mu) (units)
B 0 52323323 0 0 0 0 0 11.16 3557 1400
B 1 52318252 -20.13 -20 5E-2 -8E-2 0 11.28 12596 1213
B 2 52312960 -41.13 -40 1.07 -6E-2 0 11.33 4003 1440
B 3 52307921 -61.13 -60 1.04 -9E-2 0 11.46 3403 1251
B 4 52302220 -83.75 -80 3.8 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 : Difference in position between highest beam and
beam
Soll : target position (sollwert)
Cor : average correction during by CALIK
delta : delta between Diff.Pos and Soll - Cor
Width : beam width
Was : average beam width during CALIK
Amp : Amplitude needed for tuning to imax
Freq : Frequency setting
• Syntax: 12 3000 SFREQ
SFREQ eats two numbers from TOS:
· the first number is the beam
· the second number is the frequency
12 do dup 2 * 2 – 2200 sfreq loop ;Set all even beams on 2200
12 do dup 2 * 1 – 3800 sfreq loop ;Set all odd beams on 3800
• Syntax: SHCLOSE
SHCLOSE will close the shutter: it will turn over a fixed number of steps.
• Syntax: SHINIT
SHINIT will initialize the shutter.
• Syntax: SHOPEN
SHOPEN will open the shutter: it will turn over a fixed number of steps.
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• Syntax: SKYMAX
Finds imax(maximum amount measured on the diode) for each beam between
min frequency and maximum frequency found during LOCKRANGE_ALL in
steps of 26. This should be in the region of 4000->4095
STORE SKYMAX VALUES IN ROM (Y/N) ? Y
If you answer NO to the previous question, the following question appears on
the screen
RESET and SAVE SKYMAX TO DEFAULT MAX. VALUES(Y/N) ?
answer N or tickoff to continue.
• Syntax: 3000 0 TNB
Used for auto optic tuning (using feedback diode).
TNB eats two numbers from TOS:
· the first number is the intensity setting (par.91)
· the second number is used for the shutter verify option
· 0 : SHINIT SHOPEN is executed, without shutter verify
· 1 : SHINIT SHOPEN is executed, with shutter verify
Syntax: defaults
Allows to set defaults for multibeam optics. This command 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 > defa u l t s
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 option "T"
Defaults for DELAYS [Y/N] ?
depending on base resolution and default YSIZE
Defaults for TUCOR [Y/N] ?
TUCOR for all the beams is set on value 1000
Reset knife_corrections [Y/N] ?
Upgrade knife_corrections optics300-->600 [Y/N] ? n
Defaults for legal ppi [Y/N] ?
Defaults for lock range [Y/N] ?
Defaults for SKYMAX [Y/N] ?
Do not forget PROPAR if you want to store these values
Parameters
• Syntax: CLRYCOR
It is possible to clear the drum correction table with one command:
LTL > CLRYCOR
Clearing ysize table !!! ... Are you sure [Y/N] ?
Clearing yoffset table !!! ... Are you sure [Y/N] ?
• Syntax: COPYPAR
COPYPAR is used to copy LTL-parameters between 2Maccon boards.
Syntex: CLRYTAB
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CLRYTAB resets the table indices (pointers) to the beginning of the table.
This command must be executed before filling in the Y-SIZE or Y-OFFSET
correction tables.
• Syntax: CREYSIZ
CREYSIZ 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 > CREYSIZ
HRDWINIT not allowed
Example
Creating ysize table:
LTL > CREYSIZ
Number of 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 > CREYO F FS
HRDWINIT not allowed
Example
Creating yoffs table:
LTL > CREYO F FS
Number of input points : 3
CARPOS1 : 100e6
CORRECTION1 : 0
DELTA-CORRECTION1 : 1
CARPOS2 : 200e6
CORRECTION2 : 33
DELTA-CORRECTION1 : 1
CARPOS3 : 300e6
CORRECTION3 : 0
LTL > PROYOFFS
Storing parameters ...
Verifying ... OK.
LTL >
Syntax: GETYOFFS
Loads the existing Yoffs table in RAM memory
• Syntax: nr DISYOFFS
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Displays yoffset table (2048 points max) from nr (1 <= nr <= 2049).
Syntax: GETYSIZ
Loads the existing Ysize table in RAM memory
• Syntax: nr DISYSIZ
Displays ysize table (2048 points max) from nr (1 <= nr <= 2049)
• Syntax: GETPAR
Definition: Restore saved machine params
• Syntax: PROPAR
Definition: Store machine params in eeprom
• Syntax: PROYOFFS
PROYOFFS will save the new values of the Y-Offset table from the RAM of
the Maccon board into the EEPROMS on the Maccon board.
• Syntax: PROYSIZ
PROYSIZ will save the new values of the YSIZE table from the RAM of the
Maccon board into the EEPROMS on the Maccon board.
• Syntax: SECOR
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 SECOR IN ROM [Y/N] ?
Check for stable average !
Check : Laser Tool Language Updates !
• Syntax: SHWPAR
Allows to show and modify the plotter parameters in the RAM of the Maccon.
LTL > SHWPAR
Parameter ver 3.2 your choice:
• Syntax: DUMPPAR
Dump all parameters to screen.
Added to LTL ‘m6v12s94’
Pump
• Syntax: 1 DRMVAC
DRMVAC eats a value (1/0) from TOS and turns the Vacuum Pump on/off.
• Syntax: 1 VACUUM
VACUUM eats a value (1/0) from TOS, enabling high vacuum in the drum.
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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
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Film Feeder
Adjusting the Film Feeder.
Filmfeeder commands
LTL >?feeder
1 SFDREL : take over cylinder forward
2 SFDREL : roll down
4 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
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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 IODET . : 0 ---> spare
7 IODET . : 0 ---> spare
8 IODET . : 0 ---> spare
Drum vacuum
Dual relief valve system :
Low and High Vacuum Settings.
Low vacuum : during film loading
High vacuum : during exposing
• Adjusting the two fisher control valves sets the two vacuums.
• First check if the vacuum pump is connected electrically and vacuum wise.
1. Put the low vacuum on with the 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 around the drum.
2. Type in the command “1 VACUUM”.
3. Read the value on the vacuum sensor. This value should be around 220 mbar.
If this is not the case, adjust the position of the spring inside the second fisher
control valve until you have the correct value.
Single relief valve system :
Place a film around the drum.
Read the value on the vacuum sensor. This value should be around 220 mbar. If
this is not the case, adjust the position of the spring inside the second fisher
control valve until you have the correct value.
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Drum Vacuum adjustment by the Relief Valve:
When opening-loosening the top part of the relief valve the spring can be seen for
adjusting the drum vacuum. Adjusting the screw more to the bottom the vacuum will
increase. Bringing the adjustmentscrew more to the top the vacuum will decrease.
Don’t forget to close the valve again !!
Model PG30 – Drumvacuum
:
To adjust operation mode
• Press 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. The settings are stored.
Adjustment of settings vacuum switch
• Press M and ↑ key together
LED under sw1 flashes on and off
With ↑ and ↓ key you can adjust the level to -40 mbar !!!!!!!! Negative
This is the vacuum level were sw1 will switch on.
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• Press the M key again
LED under sw2 flashes on and off.
With ↑ and ↓ key you can adjust the level to the same value when half of the
film is off the drum. So it means that when a film is loaded and you will
remove half the film off the drum the machine should detect it. OR
high
vacuum detection value is set between the vacuum value without a film and
the vacuum value with film.
Ex.: vacuum with film = 220mbar
vacuum without film = 190mbar
high vacuum detection is set to 205mbar
This is the vacuum level were sw2 will switch 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”
Connections
Brown: +V 10.8… 30VDC
Blue: common
Black: switch1(pnp 30V 100ma max)
White: switch2 (pnp 30V 100ma max)
Gray: analog (0-5V)
Error messages:
E-1 Overload current is flowing. LED of overloaded SW1 and/or SW2 blinks.
E-2 Pressure is applied during zero adjustment.
E-3 Setting conditions are not satisfactory.
E-4 This error should not appear.
--- pressure indication is exceeded.
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Suction caps vacuum
Kavak censor :
Make sure the feeder bridge is down “8 rfdrel”. Cassette must be empty.
Switch on the vacuum in the suctioncaps “128 sfdrel”.
Adjust vacuum detection untill ‘led 8’ on the feeder board is just ON.
TEST: Film in cassette – bridge down – 128 sfdrel ➭ film must be detected :
‘7 feedet .‘ must return 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 -300mbar
Hystereris 10
• Press M and ↓ key together. 721
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.
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Led flashes under sw1
With ↑ and ↓ key you can adjust the value to 2.
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. The settings are stored.
Adjustment of settings vacuum switch
Press the M and ↑ key again
LED under sw1 flashes on and off
With ↑ and ↓ key you can adjust the level to -300 mbar!!!!!!!!Negative
This is the vacuum level were sw1 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 automatically zeroed.
Sw1-Sw2: ON = no vacuum detected
+/-: “- = vacuum” “+ = pressure”
Connections
Brown: +V 10.8… 30VDC
Blue: common
Black: switch1(pnp 30V 100ma max)
White: switch2 (pnp 30V 100ma max)
Gray: analog (0-5V)
Error messages:
E-1 Overload current is flowing. LED of overloaded SW1 and/or SW2 blinks.
E-2 Pressure is applied during zero adjustment.
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E-3 Setting conditions are not satisfactory.
E-4 This error should not appear.
--- pressure indication is exceeded.
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Mechanical.
2
1
Speed adjustment film bridge
Speed controller: pneumatic device to adjust the amount of pressure
Rotary actuator: Making a rotation by means off pressure
Adjust the speed of the film bridge.
1. Close both speed controllers and on the rotary actuator.
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 bridge up with the command
“8 SFDREL” and lower it down again with the command “8 RFDREL”
Rotary
Actuator
Speed
Controller
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Adjusting the reed switches on the rotary actuator
Adjust the position of the reed switch of the rotary actuator when the film feed
bridge is in the lower position. This gives a short circuit between the 2 wires of that
reed switch. You can check this with an ohm meter or in LTL by typing “3
FEEDET .”. It should display zero as the result.
Adjust the reed switch of the rotary actuator when the film feed bridge is up. Again
this should give a short circuit checking it with a ohm meter or displaying a zero as
result by typing the command “2 FEEDET .” in LTL. Adjust it in such a way the
detection is positioned in the middle of the detection area.
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
some bottom parts of the granit are not touching the frame so the granite rests on
the three bearing balls. If so you can adapt the height a bit more than 100mm.
When the correct height is reached you must fix the lower ball bolt with the nut.
Note: When adjusting the height of the ball bolts, first put compressed air in the air
cushions with the command “16 SFDREL” so that no heavy weight is on the ball
bolts.
3. Air bags pressure is around 2,4 bars. Never adjust higher than 4 bar !
3
4
5
1
0
0
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Adjusting the Film height of the cassette
The height of the films in the cassette is adapted by changing the position of
the horizontal film bar holder. For filmsizes: 24-25-26-27-28 inch around the
drum.
Adjust the Film position in left/right
First adapt the cassette to the correct filmwidth by changing the position of the
filmfeeder guiding bars. Check if the film is perfectly in the middle of the
drum.
You can adapt this by moving the complete feeder left or right. For this loosen
the eight screws of the two filmfeeder feet and position the complete feeder so
that the film is perfectly in the middle of the drum.
Take over cylinder
1. Check if the take-over cylinder hits the take-over bar.
2. This is very important because the film should remain upright during the load
process.
3. Ensure that the film feed bridge is down.
4. Proceed as follows:
LTL> 8 RFDREL (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 caps. If this is
not the case than you should decrease the distance of the bridge up position
towards the take-over plate. Decrease the distance in small steps and ensure that
the distance is equal on both sides.
6. Adapt the speed of the take over cylinder going forward if necessary by turning
the third speed controller.
Film bridge down adjustment
1. Bring the filmbridge in his down position.
2. Move the feederplate as far as possible to the front.(just before mechanical stops
which are installed in left and right top corner of cassette)
3. Adjust the position of the filmbridge so that the suctioncaps are halfway pushed
in.
4. Adjust the hydraulic shock absorber. See below.
5. Do not forget to fix all screws.
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Hydraulic shock absorbers
1. Adjust the depth of the two hydraulic shock absorbers.
2. Check this by putting the film bridge up and down manually.
3. The perfect depth is if the film bridge doesn’t touch the housing of the shock
absorber.
4. Try to keep a distance of approximately 1 mm between the housing shock
absorber and the film bridge.
5. This is for the upper and lower shock absorber.
6. Remember to fix the nut of the shock absorber.
Take over table
1. Adapt the position of the take-over table so that it lies parallel to the surface of the
drum.
2. The distance between the drum surface and the take-over table is a function of the
spoiler in the drum.
3. The surface of the take-over table and the surface of the spoiler should be in one
plane.
4. Adapting the position of 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 the equal distance left and right between take-over table
and the surface of the drum.
7. Do not forget to tighten the eight screws of the film feeder.
8. Enter the command “8 RFDREL and 1 RFDREL” this resets the valves of the film
bridge and the take over cylinder.
Activating blowpipe
This blowpipe was designed to separate films. It is situated at the top of the
filmfeeder. Airflow can be adjusted by a air speed controler which is connected in a
tube on the left side of the blowpipe.
The blow pipe is activated just before the filmfeeder bridge moves up.
Also see explanation of parameter 56 ‘Push blow plate before loading’.
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The load position
Search the value for parameter 41. This parameter brings the drum during loading
into the load position.
The higher the value, the more distance there will be between the spoiler and the
top edge of the film.
1. Bring the film up with the commands “128 SFDREL” and “8 SFDREL”.
2. Perform the take-over movement with “1 SFDREL” and “128 RFDREL”.
3. Search now the value with the following command “x ROTA”, where x the value
of parameter 41 is.
4. Do a final loading of a film and check that the movements are correct.
Remark : -Adjust the top of the drum spoiler towards the top of the film.
If the film is not parallel to the spoiler we have to adapt the
eccentrics on the left and right side of the cassette.
- Distance “spoiler
filmedge” is drumdepending. Important is
that the other side of the film is just over the last vacuumslits.
Between 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 vacuum sensor.
The value of the low vacuum without a film on the drum should be around 70
mbar. If you use a MF with a two valve system.
The high vacuum detection with a film complete around the drum should be
adjusted to the vacuum value when half of the film is off the drum. So it means that
when a film is loaded and you will remove half the film off the drum the machine
should detect it..
Check the commands “?VACON .” and “?VACHI .”
When the results are 1, then the vacuum detection is working correctly.
You can also check the vacuum sensor.
V-belt stepper motor
• The position of the V-belt must be exactly in the middle off the V-disc.
• The V-disc may not touch the the stepper motor when at rest.
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• When the stepper is activated with the 4 sfdrel command then the stepper is
against the v-belt and when you hold the ERTA gear wheel, the V-belt may not
slip.
Motor and pulley are dynamically balanced : Please do not change pulley between
motors because this can cause severe vibration problems
The motor can be lowered or 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 a ohm meter or displaying a
zero as result by typing the command “1 FEEDET .” in LTL. Adjust it in such a way
the detection is positioned in the middle of the detection area.
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The Upper Roll
• Switches off the compressed air inside the machine. (LTL>0 comsup)
Check if the roll is not dirty or damaged.
• Align the upper roll assembly mechanically until the roll becomes parallel to the
drum.
• Change this position by loosing the screws which are fixing the roller assembly on
the drum bearing blocks.
• Take care that you do not hit the drum surface with the unload table.
• Be sure to tighten the 4 screws very well.
Adjustment of the duplex cylinder (B440718)
The yellow roller has two positions. One position is just above the film(loading)
controlled by longest cylinder(2 sfdrel) and the second position is against the
film(unloading) controlled by both cylinders(2 sfdrel 8 siorel)
• Turn both shafts of both cylinders completely in.
• We will first adjust the roller to the rollerloading 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 com sup”.
• The command to let the upper roll down is “2 SFDREL” and for going up “2
RFDREL”.
• Perform those commands several times and at the same time open the speed
controls little by little until the desired speed is accomplished.
• Adjust the end position of the roll when it is down.
• Turn the shaft of the cylinder until the desired distance is reached. The perfect
distance between the roller and a film is when the roller is softly touching the film.
Be sure to seal the shaft of the cylinder with the nut.
• Check the distance always with compressed air on and performing the commands
“2 SFDREL” and “2 RFDREL”.
• We will now adjust the roller to the rollerunload position.(2 sfdrel 8 siorel)
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• Adjust the speed and the depth of the roller. In the front of the subrack there are
several speed controllers. The fourth speed controller (from top) controls the
speed of the roll coming down. The sixth speed controller (from top) controls the
speed of the roll coming up. First close them both.
• Take the roller to the rollerloading position. (2 sfdrel)
• The command to let the upper roll in extended position is “8 siorel” and for going
back “8 riorel”.
• Perform those commands several times and at the same time open the speed
controls little by little until the desired speed is accomplished.
• Adjust the end position of the roll when it is down.(2 sfdrel 8 siorel)
• Turn the shaft of the cylinder until the desired distance is reached. The perfect
distance between the roller 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 then the roll is down. Please note that
both detection’s must work correctly, because they are interconnected.
Film Bridge Sensor Adjustment
Be sure the filmbridge down position is correct adjusted.
Bring the filmbridge in his down position. (8 rfdrel)
Move the feederplate as far as possible to the front.(just before mechanical stops
which are installed in left and right top corner of cassette) (‘1 & 2 iorel’
command)
Adjust position of the sensor by turning the screw in the front side of the
feederplate. Turn the sensorscrew untill the cassette is detected. One can
use the command ‘2 iodet .’ to check the detection.
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Flap end backward Adjustment
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
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Checking the in-line and on-line detection’s
In-line
:
LTL> do 4 feedet . 5e5 wait tilkey
0 -> no film detected
1-> film detected
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.
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The Film Feeder Parameter Settings
41 Drum load position : 7394
This parameter controls the load position of the drum. This is the physical position
where the upstanding surface of the spoiler lies a short distance above the
film edge when the film has been presented to the drum using the film feeder
bridge. Distance “spoiler
filmedge” is drumdepending. Important is that
the other side of the film is just over the last vacuumslits. Between 1 and 2
millimeter.
42 Drum unload position : 811
This parameter controls the unload position of the drum. This is the physical position
where the beginning of the film lies about 1 cm before the unload table,
mounted on the roll down system.
43 Unload to inline distance : 4000
This parameter can be left to the value of 4000. This parameter ensures that during unload the
first detector in the in-line system should recognize the film before the drum has rotated the
parameter steps. In this case 4000 steps. If it doesn’t see the film the following message
appears:
Warning Recovering film transport to inline
Warning Recovering film transport 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.
45 Drum stepper acceleration : 6000
This parameter can be left to the value of 6000. This controls the acceleration of the
stepper motor during unload and positioning drum during load.
46 Load alignment distance : 0
This parameter controle the alignment distance during load. This parameter can be left
to the value of 0.
47 Film from drum release time (ms) : 5000
This parameter controls the extra wait time during the unload p r ocedure before the film is pushed
up to the unload table.
48 Wait before take over (ms) : 1000
This parameter controls the extra wait time before the take over cylinder is pushed
forward. Normally the software detects when the film feeder bridge is
up. But this doesn’t mean that the film feeder bridge is physically at it’s
end position. This depends on the location of the reed switch on the
rotary cylinder. This extra delay can be compensated with this parameter.
This parameter can be left to the value of 1000.
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49 Wait after take over (ms) : 3000
This parameter controls the extra wait until the next step in the load p rocedure is performed until
the take-over cylinder hits the take-over table. The speed (and time) that the take-over cylinder
hits the take-over table is controlled via the third speed controller. The slower the speed the
longer it takes to hit the take-over table the higher the value of this parameter should be.
This
parameter can be left to the value of 3000
50 Load drum stepper period : 1200
This parameter can be left to the value of 1200. This will give you the speed of the
stepper motor during the winding of the film around the drum during the load
procedure. The higher the value, the lower the stepper motor speed.
51 Load drum stepper acceleration : 600
This parameter can be left to the value of 600. This controls the acceleration of the
stepper motor during the beginning of the winding of the film around the
drum during the load procedure. This value can supply a slow acceleration of
the stepper motor. A lower value compared to the unload acceleration is
needed, otherwise the chance of loosing the film at the start of the winding is
higher.
52 Wait after suction caps off (ms) : 2 000
This parameter controls an extra delay 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 winding the
film around the drum. If the correct vacuum level is not reached in time, the
chance of loosing the film during the winding of the film around the drum is
higher.
54 Timeout inline to online (ms) : 20000
This parameter can be left to the value of 20000. This parameter sets the time that
the film has to reach from the I.R. detector in the inline to the I.R. detector in
the conveyor in normal procedure. If the I.R. detector of the conveyor
doesn’t recognize the film in time then it will shut off the motors of the two
transport systems. This is needed if your working in backup mode (= second
transport system is put up so that the films drop in the unload drawer).
55 Timeout online to processor (ms) : 30000
This parameter sets a timer that starts running when the I.R. detection of the
conveyor recognizes the film. The time indicated in this parameter is the time
that the film has to clear from the I.R. detector. If this is not the case, the
motors of both transport systems are shut off. If the film stays over the I.R.
detector, the second transport system will goes into backup mode.
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56 Push blow plate before loading (ms) : 4000
This parameter controls the option of activating the blowpipe for a certain time.
The purpose of this is to separate sticking films. If this is used be sure the
airflow is correct(4 siorel).
57 Drum vac release offst from ldpt 1 : 300 ;28”
This is a very important parameter if you use the option of vacuum releasing after
loading. This option is set to on if parameter 71 (Vac off time after load) is
not set to zero. This parameter sets the drum to a certain position so that the
vacuum can be released for a certain time without film dropping from the
drum.
For 28 inch the position of the drum is so that the end of the film(tail) lies as
close as possible to the beginning of the unload table without the chance that
the end of the film is moved away when the unload table comes down. At
that position, the beginning of the film(spoiler) is at the position of the
yellow roller.
58 Winding dis after vac. release :
After releasing the vacuum the vacuum pump is switched on again. It is
possible 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 the time needed for the
roll to come down and touch the drum is longer than the time that the vacuum
is dropped to zero. If extra time is not provided, then the film becomes
completely loose and this is a potentially dangerous situation.
60 Par45 from MM220 vac. pump [0/2]: 0
USED FOR SINGLE FILMFORMAT
This parameter controls the same value as parameter 45 of the MM220 of the
vacuum pump. The parameter 45 determines if the 2 frequencies (load and
spinning vacuum settings)need to be added or subtracted. This information is
important for the vacuum release procedure. The highest physical vacuum
available is required after relaxing the film to roll the film again around the
drum.
61 Frnt rol pos after flm rel (0=off): 2502
This parameter is the position where the film rol is coming down after relaxing the
film. This is the spoiler position.It can be found with the drmpos . command.
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62 Back rol pos after flm rel (0=off) :2015 ; 28 inch
This parameter is the position where the film rol is coming down after relaxing the
film.This second position is the end position of the film.It can be found with
the drumpos . command. Parameter 62 is for a 28 inch film around the drum.
63 Back rol pos after flm rel (0=off) : ; 27 inch
See explanation of parameter 62
64 Back rol pos after flm rel (0=off) : ; 26 inch
See explanation of parameter 62
65 Back rol pos after flm rel (0=off) : ; 25 inch
See explanation of parameter 62
66 Back rol pos after flm rel (0=off) : ; 24 inch
See explanation of parameter 62
67 Wait after l oader back multif ormat : 0
Not used
68 Drum vac release offst from ldpt 2 : -980 ;27 inch
This is a very important parameter if you use the option of vacuum releasing
after loading. This option is set to on if parameter 72 (Vac off time after load)
is not set to zero. This parameter sets the drum to a certain position so that 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 releasing
after loading. This option is set to on if parameter 73-85-86 (Vac off time after
load) is not set to zero. This parameter sets the drum to a certain position so
that the vacuum can be released for a certain time without film dropping from
the drum.
For 24-25-26 inch the position of the drum is so that the end of the film(tail)
lies as close as possible to the beginning of the unload table(or still holded by
the yellow roller if possible) without the chance that the end of the film is
moved away when the unload table comes down. At that position, the
beginning of the film(spoiler) is at the position of the suctioncaps.
For a 24 inch film Single Format SilverWriter the tail of the film must just be
held by the yellow roller. See also explanation of parameter 58.
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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
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Load process
Description of the different parts.
The drum: The goal is to wrap a medium like a photosensitive film around
the drum. This medium is held on the drum by a high vacuum. This is
needed because the drum spins at a high speed. During the spinning of the
drum, an image is written on the medium using a laser source that is
mounted on a carriage. This carriage travels from left to right, so in the
axial plane.
Take-over plate: The goal is to ensure that the medium has no tension
around the drum. Therefore this take-over plate is needed. This plate lies
parallel to the surface 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 caps, a take-over
cylinder and bridge sensor are mounted.
Take-over cylinder: This cylinder ensures that the film is tension free.
When the film bridge is in the up position, the position of this cylinder is
the same height as the take-over plate. At a certain time during the load
process, the film will be held on only one point .
Film size adapters: With three adapters the load cassette for different film
sizes can be adjusted.
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Position of the 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.
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Taking up the film and positioning the drum.
During this phase the feeder plate moves towards the film bridge. A vacuum is put on
the suction caps. The home position of the film bridge is fixed. In that situation 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 of the drum. The software detects which side is the shortest .
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Moving up 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.
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Take-over action.
When the film bridge reaches upper position, the take-over cylinder is pushed towards
the take-over plate. After this the take-over cylinder 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 tensionless.
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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.
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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.
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Moving the drum 1 turn.
The drum spins clockwise(viewing from the right) one complete turn at a low speed.
After the turn of the drum the film is relaxed by releasing the drum vacuum and
after some time the drum vacuum comes back on to suck the film back on the
drum.
Depending on the filmsize we have two different drumpositions 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 62-6364-65-66 ) of the feeder parameters.
Par 61 is the drumposition where the rol comes down in the spoiler
Per 62-63-64-65-66 is the drumposition where the rol comes down on the end of
the film.
Par 57-68-69 : see explanation in part ‘The Film Feeder Parameter Settings’.
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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.
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Unload process.
Description of the different parts.
The drum: The goal is to transport an exposed medium, like a
photosensitive film, from the drum to a developing machine or an unload
tray. During the expose the medium is held on the drum by a high vacuum.
Entrance vacuum: The high vacuum is generated by a vacuum pump and
via a flexible tube connected to the drum. The connection at drum side is
central to the drum and made out a non-friction coupling.
Exposed medium.
Holes in drum: At the beginning of the film a special hole pattern is made
in the drum to keep the film fixed on the drum during 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 connected with the first holes through a vacuum
channel. So there is suction force on the film around the drum.
Upper roll. Holding the film during unloading.
Unload table: This table puts the film on the transport mechanism.
Transport mechanism: This brings the film towards an unload tray or
developing machine.
Unload bottom plate: During load the film hits this plate. Plate is made
from a special material so that no scratches are made on the film.
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Moving drum to the unload position.
The drum first rotates 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.
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Putting the table and upper roll down.
At the same time the upper roll and the unload table moves towards the drum.
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.
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Releasing of the high vacuum.
The high vacuum is deactivated. This means that the suction force is gone. The film
no 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.
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Rotation of the drum clockwise.
Because the position of the beginning of the film is higher than the unload table and
the upper roll gives us a driving power, the film is pushed up to the table when the
drum is rotated. This happens with a relative high speed.
During this movement the end of the films is dragged along the unload bottom plate.
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 is no longer between the upper roll and the drum, the
largest force is the friction force of the transport mechanism. So the speed of the film
now becomes the speed of the transport mechanism.
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Resetting the mechanical parts.
After the film is completely installed on the 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)
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Vacuumpump
Danger.
The vacuum pump box use dangerous electrical voltages.
For safety , the vacuum pump box is earthed.
Only Diagnostics and Advanced Service Personnel should work with this
equipment. These personnel 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 connection 3x6mm² or AWG10 (cable should be rated for 600V)
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The Vacuum Pump Box Components/Layout.
FIRST LAYOUT
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SECOND LAYOUT
The following components are used:
• vacuum pump Siemens: 2BH1800-1AK13
• additional silencer: 1BX1055
• Motor Controller 3RW3034-1AB14
• Thermal protector 3RV1031-4AA10 (16A)
• Thermal protector 3RV1031-4EA10 (32A)
• fans: PAPST 3950
• multi-pin connector: H-A3
• Separate electrical connection 3X6mm²
Specifications 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 60Hz
3-phase 380-460V ±10% (12.5A), 50 or 60Hz
Customer power supply cable: 3-phase 230VAC _ 4x6 mm² rated for 600VAC
3-phase 380-460VAC _ 4x4 mm² rated for 600VAC
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Height: 800 mm (31.5 inch)
Width: 800mm (31.5 inch)
Depth: 1300 mm (51.2 inch)
Weight: approx. 150 kg (330 lbs.)
Noise level: 75 dB(A)
Heat : 2.7kW at 250mbar
Ouput: 50 °C
Environmental Conditions: Temperature : 5 °C < T < 30 °C (41 °F < T < 86 °F)
Relative humidity: < 80% no condensation
Remark:
Dear all,
Please be advised of the following:
• !!!! all MultiFormat SilverWriters leaving the factory have the vacuum
pump unit cabled for 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 230VAC
Reason why this is done this way is that when the SilverWriter is being build,
production doesn't know 100% for sure where this plotter is going to; so they
wire it for 380VAC which is the safest solution from an electrical point of view.
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The electric diagram of the vacuum pump box is seen in next picture.
The Siemens Motor Starter 3RW3034-1AB14.
Description.
Electronic motor starters are build for soft start and soft stop of asynchronous motors.
A thyristor bridge takes over during start and stop.
While running you have a normal relays working.
Build to drive pumps ,compressors ,transport beld .
Specifications:
Start time t
R 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 t
R 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: 110VAC to 230VAC 50/60Hz.
Starts/hour: 20 starts/hour
Ambient Temperature: -25°C to +60°C.
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The Thermal protector 3RV1031-4AA10 /3RV1031-4EA10
Thermal protector for vacuum pump.
2 types are used:
Wired for 230V or wired for 460V.
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
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MF Electrical Solid State panel
Used for:
Film detection Bridge. Input detection 3 Is one when film is detected
End detection Film plate. Input detection 1
(Flatcable) Is one when film plate back is detected
Start/stop Motor Film plate. Solid state number 1(at det SS) SIOREL/RIOREL 1
0 motor stopped
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/RIO REL 8
RMF1 : Motor direction
RMF2 : Motor activating
G101300
G101290
G
10124 G2480620
G2480630
G248632
G2486240
V3247183
G2708820
B331103
G2486232
G2708810
G185960
B361622
G2524460
R
MF2
R
MF1
MF+
MF-
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MF Relief valve system
Consists of 2 2” valves.
1 of them is adjusted so that there is 70mbar vacuum inside the drum.
1 of them has to be adjusted for high vacuum level (about 220 mbar vacuum inside
drum)
System:
While loading a film a low vacuum is needed of 70 mbar.
Ones the film is around the drum the valves are closed by means of the 1 vacuum
command. 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
adjusting the drum vacuum. Adjusting the screw more to the bottom the vacuum will
increase. Bringing the adjustmentscrew more to the top the vacuum will decrease.
Don’t forget to close the valve again !!
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SilverWriter MF Valve System
3 extra 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
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MF SilverWriter SUPPORT ROLLER
The Single cylinder (G2704030) is changed by a duplex 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
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SilverWriter MF Pump CONTR box
Controller box 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
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Filmsize adjustment on MFF
Imager
• Loading – Filmpositioning cassette: Adjust the cassette to the correct filmsize.
• Unloading - Filmpositioning unloaddrawer.
Unload drawer
Air inlet
Electric connection
&Mainsw
itc
h
Vacuu
m
inlet
Film outp ut
towards process or
Manual film input
for processor
Transport control
& indic ation
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Parameters
• Filmfeed parameter 70 = For testing the filmfeeder (in LTL) with the correct
filmsize. And loading a filmsize with the correct parameters.
70 Film in use in LTL mode:
Filmsize around drum
0&1 = 28 inch
2&3 = 27 inch
4&5 = 26 inch
6&7 = 25 inch
8&9 = 24 inch
For a 26inch filmsize around the drum ‘parameter 70’ is 4 or 5.
For a 28inch filmsize around the drum ‘parameter 70’ is 0 or 1.
When ‘4’ is used than the next parameters will be used : Par 79
Par 73
Par 69
Par 64
When ‘0’ is used than the next parameters will be used : Par 3
Par 71
Par 57
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 filmt6 (1/6400 mil): (25inch)
82 Chart home pos filmt7 (1/6400 mil): (25inch)
83 Chart home pos filmt8 (1/6400 mil): (24inch)
84 Chart home pos filmt9 (1/6400 mil): (24inch)
• Par 71-72-73-85-86 = Blower(vacuum pump) off time after film load.
71 Vac off time after load 28''(ms):
72 Vac off time after load 27''(ms):
73 Vac off time after load 26''(ms):
85 Vac off time after load 25''(ms):
86 Vac off time after load 24''(ms):
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• Par 57-68-69 = Drum position during relaxation.
57 Drum vac release offst from 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''):
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Resource files
During exposure parameter70 is not used. For loading a filmsize with the correct
parameters a parameter called ‘setting’ is used. This can be found in the
‘PowerRip.res’ file and ‘PR_recorder.res’. You must define the correct filmsize in
the ‘PR_film.res’.
Ex.: Setting: 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 8000
ovsp : 1 1
ovsp_asym : 0 0
ovsp_abs : 0 0
jobreg : C,C
negbord : 1
negbordsiz : 500
pinzone : 0,0
setting : 400
autoload : 2
filmreg : C
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• PR_film.res
-Adding the correct filmsize.
[26X26]
sizevh: 26000 26000
type: pos
name: AmphiWriter
• PR_recorder.res
-Adding 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.
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What a customer has to do when changing filmsize
→
IMAGER :
For 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
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
………………………………………………………………………………………
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Electrical Devices
Power panel
With MM750
With MM440
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Circuit breakers
Circuit braker overview:
CA: switch laser power supply (16A)
CB: protection laser
CC: protection ventilators+ext. lamp
CD: protection vacuum pump
CE: protection P.S door ,main valve
SP: From sn105 surge protectors installed
CF: switch elektronic rack (10A)
CG: protection comut+ el.rack
CH: protection rip (not with PowerRip )
S
P: 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
• Rated voltage:690V
• Rated current:16A
• Rated frequency: 50/60Hz
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Film feeder solid state panel
Solid state Panels.
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Power 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
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Multi FilmFeeder solid state panel
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Drum Micro Master Parameter Table MM750
Warning:
All settings should only be entered by qualified personnel, paying particular attention
to the safety precautions and warnings.
MM750 : makes the drum spinning during exposure. Drumdirection: when standing
on the right of the SW(drummotor position) the drum spins clockwise during
exposure.
To enter the parameters into the Micro Master you have to use the three
buttons and the 4 digit LED display:
P
Use this button to toggle between parameter number and parameter
value.
Use the white button up to set parameter numbers and values to
higher values.
Use the white button down to set parameter numbers and values to
lower values.
P000 ==> P944 : Parameter numbers
0000 ==> 9999 : Parameter values
F000 ==> F154 : Fault codes
parameter: 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
P052 : 5 selection control function
P061 : 4 brake active
P062 : 1 converter active (drum spinning)
P064 : 5 additional brake time in sec. (assure full stop)
P075 : 200 value of the brake resistor (Ohms)
P081 : 50 * motor nominal frequency (Hz)
P082 : 1410 * motor nominal speed (rpm)
P083 : 3.6 * motor nominal current (I)
P084 : 220 * motor nominal voltage (V)
P085 : 0.75 * motor nominal output (kW)
P086 : 150 motor current limit (%)
P087 : ? PTC enabled
P088 : 1 ! enables autocalibration (has to be done once)
P089 : x.x ! stator resistance (measured during calibration)
P122 : 0 disables forward/reverse button
= : This frequency should give you a certain drum speed.
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+ : Set this parameter to 3 if you want to change parameters > 9. If the
machine is shipped to the customer set this parameter to value indicated in the
list.
! : Autocalibration of the stator resistance has to be done only once after
connecting the motor to the converter. This value is then stored in parameter
89.
Warning:
The value of parameter 89 should be around 8 ohms. If this not the case, set
this value to 8.
! : Autocalibration of the stator resistance has to be done only once after
connecting the motor to the converter. This value is then stored in parameter
89.
Remark:
• When parameters are set the value is automatically stored in internal 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 too fast the Micro Master
goes into a protective mode for a short time 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 or deceleration to
avoid this phenomenon.
• If P944 is set to 1 then the parameters are set to factory defaults. So be careful !!
• If P910 is set to 1 then access to parameters becomes remote (through RS485).
• Parameter 922 is the software version.
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• In the event of a failure the converter switches off and an error code appears in the
display. The last error is stored in parameter number P930.
Error list:
F001 : over voltage
F002 : over current
F003 : overload
F004 : overheating of motor (monitoring with PTC)
F005 : converter over temperature
F006 : mains phase missing
F008 : USS protocol timeout
F00 9 : 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 horizontal lines are displayed after powering up, then the Micro Master is
defective or there were EMC disturbances during powering up.
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Drum Micro Master Parameter Table MM440 0.75KW
Old series 6SE31(MM750) of micromasters became obsolete
MM440 : makes the drum spinning during exposure. Drumdirection: when standing
on the right of the SW(drummotor position) the drum spins clockwise during
exposure.
The 0.75 KW drum motor is controlled by a micromaster. In this case no additional 3 phase
power supply is needed.
• The micromaster is switched (input 5-9) on by
the output signal : DRUMON
• The micromaster is also connected to the Emergency stop button on input 6.
• The MM440 has a complete different set of 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
B441139
BREAK.RES. 200E MM440
Ref documents: Micromaster parameter list ,Operator manual Siemens ,
Warning
It is not permissible to open the equipment until
five minutes after the power has been turned off.
The DC-link capacitors remains charged to dangerous
voltages even if the power is removed.
Important
Functions of buttons may be disabled by parameter settings!
Principle
PARTCODES
DANGER
DISPLAY &
BUTTONS
230 v
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