Duplo DUPRINTER DP-440, DUPRINTER DP-430, DUPRINTER DP-340, DUPRINTER DP-330 Service Manual

Introduction

The cause of most accidents is failure to adhere to basic safety rules and observe safety instructions. It is important to prevent potential causes of accidents from occurring. In order to do so, read this manual carefully, and be sure to understand all the safety instructions and correct inspection and servicing procedures that it provides before beginning repair or servicing work.

Repairing or servicing the machine with insufficient knowledge about it could lead to unforeseen accidents.

It is not possible to anticipate and describe in a manual such as this every possible hazard that could arise in the course of repair and servicing. Therefore, besides observing the safety instructions marked in this manual and on the machine's labels, service personnel should be safety-conscious and take other safety precautions as necessary. When performing repair or service work not covered by this manual, you should obtain safety guidance from an appropriately knowledgeable person.

'Safety-related instructions

If the instructions accompanying this symbol are ignored and the machine is operated incorrectly, death or serious injury is likely to result.

If the instructions accompanying this symbol are ignored and the machine is operated incorrectly, death or serious injury, or else material damage, is likely to result.

WARNING:

CAUTION:

Examples of pictorial symbols

A " " symbol tells you that a certain action is forbidden. Precisely what is forbidden is indicated by a picture inside the symbol (in the example here, the picture means that disassembly is forbidden), or in writing at the side of the symbol.

A " " symbol means that a certain action is forbidden and/or that a specific instruction must be followed. The specific instruction is indicated by a picture inside the symbol (in the example here, the instruction is "Remove the power plug from the socket").

IMPORTANT:

NOTE:

Draws attention to important information. If this information is ignored and the machine is operated or serviced incorrectly, the machine`s performance could drop, or it could break down.

Draws attention to information that is useful for operation or maintenance of the machine, and to information about its performance, etc.

D Using the service manual

• This manual contains the following information: structure and function of major parts, disassembly and reassembly procedures, specifications, and procedures for adjustment, maintenance, inspection and corrective action. This information is current as of January

2002, and applies basically to the model DP-440/DP-430/DP-340/DP-330 DUPRINTER. From time to time, parts are changed to improve quality, performance or safety. Note therefore that in some cases, certain parts or machine structure aspects described in the text or illustrations of this manual may not be precisely the same as the product being serviced.

• Safety instructions marked with a " " (WARNINGS and CAUTIONS) are very important for

safety and must be observed.

Safety instructions

1. Cautions regarding the installation location

Installation environment

s Avoid installing the machine in places exposed to direct sunlight.

• Sunlight will cause the temperature in the machine's interior to rise, possibly leading to malfunction of the control system.

• Sunlight could cause misoperation of the sensors.

• The heat of direct sunlight could cause deformation of the machine's plastic parts.

* Also avoid installation near to a ground glass window; light and heat penetrate such windows

although they are opaque.

s Avoid installing the machine in places subject to high or low temperature or humidity.

• High or low temperature or humidity could cause the machine to operate abnormally.

Suitable temperature and humidity ranges are:

Ambient temperature: 10y430y Ambient humidity: 40%470% Optimum temperature and humidity: 20y, 65%

• If the machine is installed near to faucets, water heaters or humidifiers, or in cool (sunless)

parts of a building or in the vicinity of water sources, the paper could absorb moisture and curl, leading to misfeeds or poor image quality.

s Avoid installing the machine in places with open flames, or where reflected heat or other hot air

currents (from stoves, etc), or cold air currents from coolers, etc will strike it directly.

s Avoid installing the machine in poorly ventilated places. s Avoid installing the machine in dusty places.

s The machine should not be tilting when it is used.

• Install the machine so that it is level.

(The machine should be level to within 5mm in the front-rear direction, and 5mm in the lateral direction.)

sDo not install the machine on shaky, sloping or otherwise unstable surfaces.

• The machine could fall over on such surfaces, or fall off them, causing injury.

Safety instructions

Warning

• The machine's power supply voltage and power consumption depend on the model. Details of this are given in the tables below. The power supply voltage and power consumption for the machine are given in the table below. The machine's power supply voltage is indicated on the identification plate located on the machine's left side; the machine must be connected to a power supply of the voltage indicated.

a Otherwise, fire or electric shock could result.

If the power supply voltage is unstable or if the power supply has insufficient capacity, the machine may not operate normally. Make sure that the power supply has sufficient capacity for the system as a whole, including optional equipment.

Connect to outlet of 120V AC, 60Hz, at least 15A

With no load* At full load

Power consumption

No more than 130V AC At least 110V AC

During platemaking : 250W During printing at speed 3 (printing speed) :230W On standby : 60W

Power supply voltage

}

Use power supply meeting these requirements

Connect to outlet of 230V AC, 50Hz, at least 8A

With no load* At full load

Power consumption

No more than 250V AC At least 210V AC

During platemaking : 250W During printing at speed 3 (printing speed) :230W On standby : 60W

Power supply voltage

}

Use power supply meeting these requirements

* 120V AC model

* 230V AC model

* "With no load" - when the machine is on standby. * "At full load" - when the machine is running at maximum power consumption.

• Use only the power cord that is provided among the accessories. Insert the power cord plug firmly into the socket, so that proper electrical contact is effected.

• Install the machine close to its power supply. The outlet used should be exclusively for the machine, and have no other equipment connected to it. If an extension cord is necessary, it should have a ground terminal, and be of the following ratings: * For a 120V AC model: 130V, at least 15A, length not exceeding 5m. * For a 230V AC model: 250V, at least 8A, length not exceeding 5m.

• Never tread on the power cord or pinch it between other objects, or accidents could result.

2. Cautions for installation work

• Install the machine in accordance with the installation procedure appended to this manual.

• Lock the casters after the machine is installed.

a Otherwise, the machine could move or fall over, causing injury.

• To move the machine, push it by its mounting base.

a Pushing the printing (upper) part of the machine could make it fall over.

CAUTION

Using the optional printer stand

Safety instructions

' Precautions for safe servicing

• Always remove the power cord plug from the outlet before starting work.

a Otherwise, you could get a shock or your hands/fingers could be injured.

• However, the plug must be left connected to the outlet when performing function checks (of individual motors, a given series of operations, or electrical circuits). When motors are operated alone in function checks, interlocks are deactivated, so be aware of the conditions and positions of related equipment, and take great care not to put your hands or fingers into

moving parts.

• The cutter unit contains hazardous sharp blades. Exercise great care when inspecting the cutter unit or replacing it or its parts.

a Otherwise, your hands/fingers could be injured.

• Do not touch the drum or rollers after turning on the jog switch.

• Do not put your hands or fingers inside the machine while the drum is rotating.

a Otherwise, your hands/fingers could get caught and crushed between the drum and rollers.

' Working clothes

• Wear clothing than enables you to work safely.

Warning

' Tools

• Use tools that are appropriate for the work.

CAUTION

3. Cautions for maintenance, inspection and servicing

• The tape clusters have hazardous blades. Exercise care when inspecting or replacing the blades.

a Otherwise, your hands/fingers could be injured.

If optional tape clusters are used

Safety instructions

DLocations of warning stickers

The locations of the machine's warning stickers are shown below. To ensure safe work, read the stickers and heed their instructions. Keep the stickers clean at all times. If they become damaged or peel off, replace them with new ones.

No. Parts No. Name

Q'ty

L1-T3060 Warning Sticker 1

L5-T3020 Warning Sticker 2

e r

M7-T3030 M7-T3060

Warning Sticker 3

Caution Sticker 1

1 1

M7-T3060

CAUTION

WARNING

Do NOT put hands inside machine while it is operating. Hands could get caught up or crushed.

WARNING

● Do not remove this cover. The inside of the printer contains movable cutting instruments, contact with which could result in injury.

L5-T3020

Do NOT touch the drum or rollers when you operate the jog switch.

Do NOT put hands Inside machine while it is operatung. Hands could get caught up or crushed.

WARNING

N5-T3010

Do not touch the roller below. Your clothes etc. may be stained with ink.

CAUTION

N5-T3010

Caution Sticker 2 1

Chapter 8

Chapter 7

Chapter 6

Chapter 5

Chapter 4

Chapter 3

Chapter 2

Chapter 1

HELP Mode

Others

Troubleshooting

Maintenance / Check

Standard / Adjustment

Mechanism

Description of the Operation

Introduction

Chapter 1

z Features................................................................................12

x Specifications ......................................................................14

c Dimensions ..........................................................................16

v System Setup.......................................................................18

b Part Names and Their Functions........................................19

n Operation Procedures.........................................................26

m Option...................................................................................28

Chapter 2

Scanner Section.........................................................32

Platemaking/Master Feed/Ejection Section.............42

Paper Feed Section ...................................................62

Drum Driving Section................................................75

Press Section.............................................................81

Paper Ejection Section..............................................86

Drum Section .............................................................93

Option .......................................................................105

Chapter 3

Exterior .....................................................................108

Scanner Section.......................................................114

Platemaking/Master Feed/Ejection Section...........120

Paper Feed Section .................................................127

Drum Driving Section..............................................132

Paper Ejection Section............................................134

Drum Section ...........................................................139

Chapter 4

Scanner Section.......................................................148

Platemaking/Master Feed/Ejection Section...........150

Paper Feed Section .................................................158

Drum Driving Section..............................................163

Press Section...........................................................165

Paper Ejection Section............................................167

Drum Section ...........................................................169

Electrical System.....................................................173

Option .......................................................................182

Chapter 6

Troubleshooting Guide ...........................................188

Error Display ............................................................205

Chapter 7

Chapter 8

Electrical Parts Layout and Their Functions.........298

Overall Wiring Layout..............................................309

HELP Mode List .......................................................208

Overview...................................................................212

c HELP Mode Functions and Operation Procedures

.......213

(1)Accessing HELP Modes......................................213

(2)Guide to the HELP Mode Descriptions..............213

• HELP Mode Descriptions .....................................214

Introduction.................................................................................1

Using the service manual ..........................................................2

Safety instructions ...............................................................3

1.Cautions regarding the installation location........................3

2.Cautions for installation work...............................................4

3.Cautions for maintenance, inspection and servicing .........5

• Locations of warning stickers................................................6

Troubleshooting

Chapter 5

Guaranteed Periodical Maintenance......................184

Cleaning and Oiling.................................................184

Periodical Maintenance...........................................185

Maintenance / Check

Standards / Adjustment

HELP Mode

Others

Mechanism

Description of the Operation

Introduction

z Features........................................................................12

x Specifications...............................................................14

c Dimensions...................................................................16

v System Setup ...............................................................18

b Part Names and Their Functions................................19

1. Machine exteriors....................................................19

2. Sectional (structural) view of the machine ...........22

3. Control Panel ..........................................................24

n Operation Procedures .................................................26

1. Platemaking & Printing...........................................26

2. Multiple Image Printing / 2 IN 1 Layout Mode.......27

m Option ...........................................................................28

1. DUPRINTER Option.................................................28

(1) TAPE CLUSTER 4.............................................28

Chapter 1 Introduction

z Features

chap.1

zFeatures

Size A3/B4 printing(Printing area)

DP-440/DP-430 : A3 ( 290X423mm ) DP-340/DP-330 : B4 ( 250X355mm )

High-speed platemaking2.

High print quality3.

Align paper4.

High-performance lamp5.

Simple operation6.

Full range of necessary functions

Documents are easily enlarged or reduced.

In addition to same-size printing, there are three automatic settings for both enlargement and reduction. Further, the margin (94% reduction) function can be used for these automatic settings.

• Zoom settings : (70, 81, 86, 115, 122, 141%)

• Same-size : (100%) printing

Size A/B models

• Free zoom : 50% -500% ( 1% ) Enlargement :141% [A4/A3, B5/B4]

122% [A4/B4, A5/B5] 115% [B4/A3, B5/A4]

Reduction : 86% [A3/B4, A4/B5]

81% [B4/A4, B5/A5] 70% [A3/A4, B4/B5]

*4:

Maximum printing area of DP-340 and DP-330

is B4(2509355mm).

• Zoom settings : (64, 74, 77, 121, 129, 141%)

• Same-size : (100%) printing

Inch size models

• Free zoom : 50% -500% ( 1% ) Enlargement :141%

129% [LTR/LDG] 121% [LGL/LDG]

Reduction : 77% [LGL/LTR]

74% [LDG/LGL]

67% [LDG/LTR]

*5:

Maximum printing area of DP-340 and DP-330

is 11"914"(2509355mm).

Self-diagnosis

The machines have self-diagnostic functions. Messages for self-diagnosed errors, as well as consumable part replacement prompt messages, appear on an LCD panel.

Book shadow erasure

Shadows in the middle or at the edges of book documents can be erased.

Adjusting the Printing Position(vertical)

In addition to vertical direction adjustment.

Print the first sheet of paper.(document size : A4 )

DP-440/DP-340: 21 seconds*

DP-430/DP-330: 27 seconds*

*1:Time required to print the first sheet of paper

after the platemaking key is pressed.

A new, originally-developed superfine thermal head gives beautifully accurate reproductions of fine print and halftone photographs.

Its resolution is 400dpi in the pel path direction and 400dpi in the line progression direction.

Its resolution is 300dpi in the pel path direction and 600dpi in the line progression direction.

DP-430/DP-330

DP-440/DP-340

Adjusting the eject enables both thin and thick sheets of paper to be aligned neatly.

A long-life, high-brightness xenon arc lamp is used to illuminate the documents. Since the lamp's intensity is not affected by temperature variation*2, printing quality at low temperatures is greatly enhanced*3.

*2: The lamp is filled with xenon gas, which means

that it does not require heat to vaporize mercury, as a fluorescent lamp does, and therefore its intensity does not vary with temperature.

*3: Increased viscosity of the ink at low temperatures

results in fainter printing than at normal temperatures.

Operation is simplified by concealing occasionally-used keys under a panel, leaving just the basic function keys permanently accessible.

z Features

chap.1

User setting

Memory Function

Equipped with a memory function (for 9 items) able to memorize frequently used settings.

Optimize Print

Optimal images can be printed in times of low/high temperature by setting the temperature and the print speed.

Initial Paper Size setting

The paper size and print speed, etc., that are valid when the power is turned on can be set.

Document Memory

The last platemaking image can be memorized, and used later for platemaking without having to read it out again.

Special functions

The HELP mode items listed below can now also be used in the user mode. And the power save mode can cut power consumption.

Sorter Fine Start

Auto Clear

Pre-print

Batch Print

Auto Power Off

Auto LCD Off

Long Paper mode

Ink Circulation

Tape Cluster ( tape inserter )

Double Feed Detection

Drum selection ( A3/A4 )

Option

S2-ADF

Drum unit

A3/A4 Drum unit

Tape Cluster

PC Interface kit 2

Key card counter 4

Postcard stacker

Long paper unit

Sorter

10.

Document modes

The "Text-Photograph", "Text-Fine Lettering", "Photograph-Fine Lettering", "Screen 1 & 2" and "Photo Dark" Modes selecting, accommodating printing of a wider variety of documents.

Adjusting the contrast control

The degree of contrast for printing can be adjusted.

x Specifications

chap.1

xSpecifications

• Specifications

Model

Model name

DUPRINTER

DP-440

DUPRINTER

DP-430

DUPRINTER

DP-340

DUPRINTER

DP-330

Floor model Thermal digital master making 21 sec ( A4 100% ) 400dpi

400dpi

21 sec ( A4 100% )27 sec ( A4 100% ) 27 sec ( A4 100% )

300 dpix 600 dpi 300 dpix 600 dpi Flat bed scanner 100 sheets (64 - 128gsm) Stencil print

MAX. 297mm x 432mm 290mm x 423mm 290mm x 423mm (A3) (11.4"x16.6") 250mm x 355mm (B4) (9.8"x14") 1,500 sheets(64gsm) 1,500 sheets (64gsm) MAX: 297mm x 432mm

With Long paper unit (service part) : Max: 540mm

MIN: 100mm x 150mm

Master making method Master making interval Resolution Scanning method ADF (Optional) Printing method

Sheets, book ( max: 10kg)Document type

Document size Scanning area Image area ( max) Feeding capacity Stacking capacity Paper size

53gsm -210gsm (45kg-180kg)Paper weight 13lb - 110lb (Index) Feeding pressure adj.( 3 steps ) Separator adj. ( 3 steps ) 120 ppm ( 45-120 ppm, 5 steps)

Within operating temperaturePrint speed

100%Zoom A/B size

Inch size

Preset reduction/enlargement: 70, 81, 86, 115, 122, 141% 94% Zoom: 50 - 500% Auto zoom: 70, 81, 86, 115, 122, 141% 100% Preset reduction/enlargement: 64, 74, 77, 121, 129, 141% 94% Zoom: 50 - 500% Auto zoom: 64, 74, 77, 121, 129, 141% Vertical : +/- 15mm [ shown on the LCD by 0.5(mm)]Registration adjustment Horizontal: +/- 10mm [shown on the LCD by 0.5(mm)] Text,Photo,Text/Photo,Text Fine,Photo Fine,Screen1,Screen2,Photo DarkImage modes Contrast control : 5steps Master making density: 5 steps Contrast control Print density: 11 steps Automatic control (600ml, 1000ml)Ink supply method Drum unit exchangeColour print Roll master automatic feed Master feeding method Automatic ejection/ master rolling-up method Master ejection method 50sheetsUsed master capacity 320 x 240 dot matrix full- dot matrix LCD ( with contrast control) LCD OK monitor ( LCD graphic) Remainig master display function, remainig master ejection display function

* Specifications are subject to change without notice.

x Specifications

chap.1

Other function

Model name DUPRINTER DP-440 / 430 / 340 / 330

Image Rotation ( 90 & 180 degree) Colour Separation (equipped in online printer driver) Sorter Mode setting ( sort, no sort, group) Document Size Auto Scan Multiple Exposure ( 2, 4, 8, & 16- up.) Book Shadow Erasure ( adjustable) Memory Function ( 9 pattern of settings of control panel can be stored.) Confidential Safeguard Initial setting (when the power is turned on.) Optimize Print (

P-roller control according to user’s input of temperature and speed.

)

Online (IEEE1284 standard bi-directional parallel interface)

NB:For USB/SCSI connection, optional interface kit II is required.

Document Memory , Auto Clear Fine Start , Pre-print Batch Print Auto LCD Off Auto Power Off Ink Circulation Double Feed Detection S2-ADF [100sheets (64gsm)]Option Drum unit

Tape inserter PC interface kit II Key card counter 4 ( built-in type) Cabinet( with front door) Cabinet( open )

Power source Domestic:100V +/- 10%, 50/60Hz, 3.0A

120V :120VAC60Hz, 2.5A 230V :230VAC50Hz, 1.3 A 250W(

during plate making

),230W(

during 3rd speed printing

),60W(

during standby

)Power consumption In use: 1374mm(W) x 738mm(D) x 1089mm(H)Dimension Folded: 753mm(W) x 738mm(D) x 1089mm(H) With optional ADF attached: In use: 1374mm(W) x 738mm(D) x 1228mm(H) Folded: 753mm(W) x 738mm(D) x 1228mm(H) 119kgWeight 10 -30 degree(C)Operating temperature Parallel bi-directional interface (standard)Online Confirmed with IEEE1284 (compatibility mode, nibble mode) Printer driver must be installed in computer [ Windows95/98/Me, Windows NT4.0/2000,]

Printer driver must be installed in computer [ Windows95/98/Me, Windows NT4.0/2000,] [ Macintosh (MacOS7.6.1 - 9.1)] I/F PCB must be installed in the main unit.

USB, SCSI interface ( optional) PC interface kit II

* Specifications are subject to change without notice.

A3/A4 drum unit (DP-440/DP-430)

c Dimensions

chap.1

44000B

cDimensions

790.6

160

790.6

460

390

588.5

1013.9

664350

186.5477.5

226.5

483.5

620

1330

( mm )

v System Setup

chap.1

vSystem Setup

1. Before Installation

The machine and its optional equipment are set up as follows:

Documents prepared on a personal computer can be printed on this machine. The PC interface kit is required to connect this machine to a personal computer.

DDP system

NOTE :

KEYCARD COUNTER 4

Drum unit

: Option

TAPE CLUSTER 4

Cabinet (Printer stand)

Personal computer

S2-ADF

Sorter

Duplo Direct Print System

44000C

Panel cover

Contrast adjusting dial Scanner switch

Feed tray descend switch Inlet

Feed tray

Feed pressure adjuster lever

Supplemental paper tray

Power switch

Document cover

Glass

Vertical size scale plate

Control panel

Caster locks

Cabinet (Optional)

Feed pressure adjuster lever

Feeder guide F

Paper feed roller 1,2

Feeder guide R

Paper separator unit

Paper feed section

Feeder guide lock leverSeparat pressure adjuster screw

b Part Names and Their Functions

chap.1

440AAe

bPart Names and Their Functions

1. Machine exteriors

b Part Names and Their Functions

chap.1

Master ejection box lid release lever

Master ejection box lever

LED JOG switch 1

(Drum rotator switch 1)

Master ejection core

Master ejection sectionMaster feed section

Drum bar

Drum handle

Drum securing lever

Ink puck holder release lever

Ink puck

Master clump

Drum section

Master cut switch

Cutter

Platen roller

Thermal head

440BBe

b Part Names and Their Functions

chap.1

JOG switch 2 (Drum rotator switch 2)

Paper aligning lever

Jump plate

Top blow fun

Paper stacker guide

Paper stopper

S2-ADF connector cover (Optional)

Interface kit II (Optional)

Connectors (Optional)

Print tray

440CCe

4,8

44000A1e

b Part Names and Their Functions

chap.1

b Part Names and Their Functions

chap.1

22 23

2. Sectional (structural) view of the machine

56 7

No.

2 2A 2B 2C

Section Name Scanner section Platemaking/Master feed/ejection section Platemaking/Master feed section Master ejection section Master clamp opening/closing section Paper feed section Drum driving section Press section Paper ejection section Print tray Drum section

32page 42page 42page 54page 56page 62page 75page 81page 86page

93page

Mechanism

114page 120page 120page 124page 125page 127page 132page

134page

139page

Srandard/Adjustment

148page 150page 150page 151page 153page 158page 163page 165page 167page

169page

Description of

the Operation

44000Ae

b Part Names and Their Functions

chap.1

b Part Names and Their Functions

chap.1

24 25

3. Control Panel

EDIT key

NameNo. Function

Switches to rotate the document image for plate.

CONFIDENTIAL SAFEGUARD key

Enables confidential safeguard function.

Prints cannot be made unless a new master is made. USER SETTING key Switches to User setting list display. SPECIAL FUNCTION key

Switches to Special function list display. CURRENT SETTING key

Shows a list of current setting of the machine. SORTER MODE key Switches to sorter mode display. MASTER DARKNESS key

Switches to Master darkness control display. MASTER CONTRAST key

Switches to Master contrast control display. PRINT DARKNESS key Switches to Print Darkness control display. BOOK SHADOW ERASURE key

Switches to Book Shadow erasure setting display. MULTIPLE EXPOSURE key

Switches to multiple exposure setting display. 94% key

Reduces image to 94%.

94% key can be used in conjunction with preset zoom setting.

LCD

NameNo. Function

Displays current settings and status of the machine e.g. print volume,

and error messages in case of error. Cursor keys Selects setting item and adjusts printing position. OK key Enters specified setting. Ten keys Enter the print volume etc. TEST PRINT key Prints 1 copy to check the image position and density etc. PLATE MAKING key Starts making a master. PRINT SPEED key Switches to Print speed control display. PAPER SIZE key Switches to Paper size selection display. ZOOM key Switches to Zoom setting display. PRINT POSITION key Switches to Print Position control display. IMAGE MODE key Switches to image mode selection display. CANCEL key

Cancels settings in Special Functions etc and returns to main display. CLEAR key

Returns the print volume to 0.

Other settings on the control panel are not changed. key Enters the print and group number in batch printing.

ALL CLEAR key

Return all settings on the control panel to default.

( Press and hold at least 1 second.)

PRINT key

Starts printing. This key does not start making a master.

Printing cannot start when the lamp o the key is red.

Confirm that the light is Blue before pressing.

When equipped with optional ADF unit:

When next document is set on the ADF, next master making starts automatically

after a printing is finished.

STOP key

Stops printing.

*While the machine is not working, indicates the total print quantity

and the total master quantity.

94 ％

2Keys inside of the panel cover

n Operation Procedures

chap.1

nOperation Procedures

1. Pratemaking & Printing

ZOOM key

IMAGE MODE key

MULTIPLE EXPOSURE key

MASTER DARKNESS key

n Operation Procedures

chap.1

2. Multiple Image Printing / 2 IN 1 Layout Mode

In the normal state (when the ADF is not connected) the mode is switched by pressing the multiple printing selection key as follows.

Each press of the multiple printing selection key makes a different multiple printing indicator light up, in sequence. To set the number of images, press the key until the indicator for the desired number of images is lit.

2in1

NOTE :

When the ADF is connected, the multiple printing selection key can also be used to select the 2 in 1 Layout Mode, as shown below. To activate the 2 in 1 Layout Mode, press the key until the " " icon is lit.

2in1

m Option

chap.1

mOption

1. DUPRINTER Option

(1) TAPE CLUSTER 4

23S0029

23S0030

23S0031

43SH0104

1cm

Open out the tape cluster body.

Install the new tape. Make sure it will wind off in the

correct direction.

Lift up the lever and pass the tape through the slot.

Make about 1cm of tape protrude out of the slot.

Swing the tape cluster body back in.

Lever

Tape

Tape cluster body

m Option

chap.1

MEMO

Chapter 2 Description of the Operation

z Scanner Section...........................................................32

1. Description...............................................................32

2. Sequence of Operation...........................................33

(1) Sequence of the Scanner Operation ..................33

(2) Sequence of the Scanner Operation (ADF).......33

(3) Operation with the Document

Cover Open / Closed ..........................................34

1. Reading the Document Size...........................34

2. Reading the Document Darkness..................34

Platemaking Area for the Selected Paper.....35

Platemaking Area for the Book Shadow

Erasing Mode..................................................35

3. Function of Parts and Circuit.............................36

(1) Home Position Sensors ......................................36

(2) Document Sensor ..............................................37

(3) Document Cover Sensor.....................................39

(4) CCD / Lamps ......................................................40

(5) Scanner Unit Open / Close Detection................41

x Platemaking / Master Feed / Ejection Section...........42

Platemaking /

Master Feed Section

........................42

1. Description...............................................................42

2. Sequence of Operation...........................................43

(1) Operation when the master set ........................43

(2) Platemaking / Master Feeding ..........................44

3. Function of Parts ....................................................45

(1) Thermal Head.....................................................45

(2) End Mark Sensor ...............................................48

1. Master Setting Error Detection......................49

2. Master End Detection......................................49

(3) Master Lead Edge Sensor..................................50

(4)

Master Detection Sensor...................................51

(5) Cutter Unit.........................................................52

(6)

Master Feed Clutch (Electromagnetic clutch)..53

Master Ejection Section ...........................................54

1. Description...............................................................54

2. Circuit.......................................................................54

3. Function of Parts ....................................................55

(1) Master Ejection Sensor......................................55

1. Master Ejection Error Detection.....................55

2. Rotation Control of the Roll-up Motor............55

Master Clump opening/Closing Section ................56

1. Description...............................................................56

Operation of Master Clump Open / Close Lever

........57

(1) Structure.............................................................57

(2) Master Set / Removal Operation.......................58

(3) Clump Opening / Closing

Lever Position (A / B / C Mode) .........................59

3. Function of Parts ....................................................60

(1) A / B / C Mode Sensor.........................................60

4. Returning Operation Flowchart

When the Power is Cut Off Accidentally...............61

c Paper Feed Section .....................................................62

1. Description...............................................................62

2. Operation .................................................................63

(1) Rotation of the Paper Feed Roller and

Timing Roller.....................................................63

(2) Paper Feed Roller Drive.....................................64

(3) Driving of the Timing Roller..............................65

(4) Escape the Guide Roller.....................................66

(5) Paper Feed Length.............................................67

3. Function of Parts.....................................................68

(1) Printing Position Adjustment Mechanism .......68

(2) Double Feed Detection Mechanism...................70

(3) Elevator Top Limit Sensor.................................71

(4) Elevator Bottom Limit Sensor...........................72

(5) Paper Detection Sensor......................................73

(6) Long Paper Unit Mechanism( Option ) ............74

v Drum Driving Section ..................................................75

1. Description...............................................................75

2. Function of Parts ....................................................76

(1) Drum Stop / JAM Detection Position Sensor....76

(2) Master Set / Removal Position Sensor..............77

(3) JOG Switch 1,2(Drum Rotation Switch 1,2).....78

(4) Control of the Main Motor.................................79

1. Rotation Speed Control by Encoder Sensor ...80

2. Selecting the Speed..........................................80

b Press Section ...............................................................81

1. Description...............................................................81

(1) Press Roller Timing & Printing Area................81

2. Function of Parts ....................................................83

(1) P-Roller Sensor...................................................83

(2) Switching the Contact Pressure........................84

1. Contact pressure position sensing..................85

n Paper Ejection Section................................................86

1. Description...............................................................86

2. Function of Parts ....................................................87

(1) Paper Stripper Finger........................................87

(2) Top Blow Fan......................................................88

(3) Paper Ejection Jam Sensor ...............................89

1. Paper JAM Detection Timing .........................90

(4) Paper Ejection Belt ............................................91

1. Paper ejection belt speed.................................91

(5) Paper aligning mechanism ................................92

m Drum Section ...............................................................93

1. Description...............................................................93

2. Circuit.......................................................................94

3. Function of Part.......................................................95

(1) Ink Detection......................................................95

1. LED Display and Output Signal on

the Ink Detection PCB Unit............................96

2. "CHANGE INK" Display Timing....................97

(2) Ink Roller Up / Down Mechanism.....................98

(3) Ink Pump..........................................................100

(4) Drum Detection Switch....................................101

(5) Fine Start Mode................................................102

(6) Drum Shift Mechanism....................................103

(7) Front Cover Detection Switch .........................104

, Option .........................................................................105

(1) TAPE CLUSTER..............................................105

z Scanner Section

chap.2

zScanner Section

1. Description

The document is illuminated with the lamps, and the document reflection in proportion to the document image darkness is imaged on the CCDs through the mirror and lens. Then it is resoluted into picture elements and converted photoelectrically.Additionally the machine is equipped with 3 reflecting sensors that sense the size of documents placed on the document glass.

• The optical system gose forward (to the left) or back ward with a stop position of scanner home position sensor(PS1).

Optical System Operation

440340

• When ADF is attached, set the ADF Home Position Sensor (PS2) as the optical system stop position, and then read the document darkness.

Optical System Operation (with ADF attached)

440341

Glass

Mirror

Lens

Scanner

home position sensor(PS1)

CCD

Lamp

ADF

home position sensor(PS2)

ADF home position

sensor(PS2)

Glass

Scanner

home position sensor(PS1)

Mirror

CCDLens

Lamp

Document

cover sensor

Document

sensor 1,2,3

Document

sensor 4

Document

sensor 5

Document

cover sensor

Document

sensor 1,2,3

Document

sensor 4

Document

sensor 5

z Scanner Section

chap.2

(1)

Sequence of the Scanner Operation

(with ADF unconnected)

2. Sequence of Operation

1)When the PLATEMAKING key is pressed, the optical system moves to the left and reads the image.

Image reading begins

440344

Image reading

440342

(2)

Sequence of the Scanner Operation(with ADF connected)

440343

2) When image reading is complate, the lamp goes

out, but the optical system decelerates, then stops. Following that, the optical system moves right and returns to the home position.

3) The system is then on standby for the printing process.

When the

PLATEMAKING key

is pressed, the

optical

system will perform shading at home

position (PS1), and then move to the left.

3) After it returns, the optical system is then on standby for the printing process.

The optical system reads the image stopped at home position (PS2). When image reading is

complete, it immediately moves to the right

and returns to the home position.

Image reading

Image reading begins

440344

z Scanner Section

chap.2

When the document cover is opened at a certain angle, the document cover position sensor changes to be in the state of photopassing.

The lamps lights up.

When the document cover is closed at a certain angle, the document cover position sensor changes to be in the state of photointerrupting.

1. Reading the Document Size

The document sensors sense the document's length in the pel path and line progression directions.

2When the ADF is installed, the document size

(pel path direction) sense for ADF side.

2. Reading the Document Darkness

The optical system goes forward to read the document darkness immediately after the document size is read.

The area over which darkness is sensed is determined according to the document size sensed.

Vertical size plate

tip end

Approx. 30mm

Plate glass

Document

Darkness sensing area

(3)

Operation with the Document Cover Open / Closed

440348

z Scanner Section

chap.2

Platemaking Area for the Book Shadow Erasing Mode

When the platemaking is performed in the book shadow erasing mode, the platemaking area is limited 3 mm inner than the normal platemaking area as shown in the figure. 15mm is left in the central section (stitching section).[Shadow erasing as desired is not included.]

* During multiple image printing, the book shadow erasing mode can not be used.

Platemaking Area for the Selected Paper

2The platemaking area varies depending on the selected paper size as shown below.

* When the magnification error is 0 in the pei path

direction or in the line progression direction, the size for the same size (1:1) platemaking is shown.

A : Pel path direction B : Line progression direction

NOTE

Selected paper size

A ( Remarks

290A 414A 204 290

B4 251 358 A5 142 204 B5 176 251

LDG 273 414

LGL 210 350 LTR 210 273

STMT 172 210

MAX 290 414

11"914" 251 358

MINI 134 210

DP-440/430

DP-340/330

A4 290 204

A4 R

1%)

B (

1%)

z Scanner Section

chap.2

3. Function of Parts and Circuit

(1) Home Position Sensors

Description

PS1 detects the optical system home position when ADF is not used. PS2 detects the optical system home position when ADF is used.

Scanner home position sensor (PS1)

Main PCB unit

Red

Blue

CN11-11 2 3

1 2 3

-3

Yellow

Red

Blue

Yellow

-2

Photopassing :0V Photointerrupting:5V

Circuit

Operation

23S0214

440W01e

Photointerrupting plate

Slider A

Scanner

home position sensor(PS1)

ADF

home position sensor(PS2)

Slider A

Photointerrupting plate

Photointerrupting

plate

Photointerrupting

plate

A shading plate is attached on slider A of the optical system. The position where PS1 is shaded becomes the optical system home position when ADF is not attached. The position where PS2 is shaded becomes the optical system home position when ADF is attached.

ADF home position sensor (PS2)

Red

Blue

CN11-41 2 3

4 5 6

-6

Orange

Red

Blue

Orange

-5

Main PCB unit

Photopassing :0V Photointerrupting:5V

440W02e

• Standard (ADF not attached) • With ADF attached

z Scanner Section

chap.2

(2) Document Sensors

Description

Document sensors 1, 2 and 3 (pel path) sense the document's length in the pel path direction when it is placed on the document glass. Document sensor 4 (line progression path) / document sensor 5 (line progression path) senses the document's length in the line progression path direction when it is placed on the document glass.

A5R

B5R

LTR

A4R

STR

LTR

MINIR MINIR

LT LG

MINI

A4R

B5R

A5R

A4 B5

MINI

A5R

B5R

LTR

A4R

STR

LTR

MINIR MINIR

MINI

A4R

B5R

A5R

MINI

440345e

Document

sensor 1,2,3

Document sensor 4

( A / B size )

Document

sensor 5

Document sensor 4

( inch size )

z Scanner Section

chap.2

Document sensor 1,2,3 (pel path)

Document sensor 4 (line progression path)

Document sensor 5 (line progression path)

Light blue

Pink

CN12-11 2 3

1 2 3

-3

Light green

-2

Red

-4

Blue

-5

Green

Blue

CN12-61 2 3

6 7 8

-8

Red

-7

Gray

Blue

CN12-91 2 3

9 10 11

-11

Red

-10

Light blue

Pink

Light green

Red Blue

Green

Blue

Red

Gray

Blue

Red

Main PCB unit

Paper present :0V No paper :5V

Circuit

440W03e

z Scanner Section

chap.2

Description

The document cover position sensor detects opening and closing of the document cover (or ADF if the ADF is installed).

Operation

Sensor is photointerrupted with the document cover closed, The photointerrupter rotates as the document cover is opened and sensor is photopassed.

Document cover position sensor

Red

Blue

CN6-11 2 3

22 23 24

-3

Light green

Red

Blue

Light green

-2

Main PCB unit

Photopassing :0V Photointerrupting:5V

Circuit

(3) Document Cover Position Sensor

2When the document cover is closed

Document cover position sensor : photointerrupted

2When the document cover is opened

Document cover position sensor : photopassed

440W04e

440338

Photointerrupted Photopassed

Fulcrum Fulcrum

OPEN

z Scanner Section

chap.2

(4) CCD / Lamp

Description

The lamp illuminates the document and the reflected light is transmitted onto the CCDs.The CCDs output the image signals in level of voltage.

This machine adopts a xenon lamp which is lit quickly when turned on, and the quantity of light is stable.The lamp is lit when the the control signal CN1-1 for the lamp inverter unit is LOW (0V) .

The table below shows the specification for the CCD.

Drive PCB unit

Lamp inverter unit

CN9-9

7 8 9

-11

-10

CN1-1

-3

-2

CN12-1

-12

CN12-12

CN12-11

-1

CN2-1

-4

1 2 3

7 8 9

Gray

Brown

Blue

CCD PCB unit

Lamp

Document

Main PCB unit

Circuit

• Lamp

• CCD

Specification

No. Item Specification

Optical signal storage time (SH cycle) 2.048 msec./ line

2 Frequency 2.5MHz

3 The number of effective picture elements 4800 picture elements

Reading width (This is not the image width which can be processed.)

305mm

5 Reading density

15.7 dot/mm(400DPI)

440W05e

z Scanner Section

chap.2

Operation

When the

scanner unit

is closed, the switch is pressed; OPEN. the switch is attached to the plate spring,

which keeps the switch from too much pressure. When the

scanner unit

is open, the actuator is released; the

micro switch is turned to CLOSE.

Description

Opening and closing of scanner unit cover is detected by scanner unit cover open / close detection SW (MS3). This machine does not work (except for the master cut SW and the jog SW) unless the scanner unit is closed firmly. The machine stops immediately when the scanner unit is open. (after finishing platemaking if platemaking is being performed.)

• When the scanner unit is opened •When the scanner unit is closed

Scanner open/close SW

When the scanner unit is closed:Open When the scanner unit is opend:Close

Main PCB unit

Pink

CN4-14

-15

When the scanner unit is closed:0V When the scanner unit is opend :5V

Circuit

(5) Scanner Unit Open / Close Detection

440W06e

440339

Scanner unitScanner unit

Switch ON

Switch OFF

x Platemaking / Master Feed / Ejection Section

chap.2

xPlatemaking / Master Feed / Ejection Section

Make the master clump of the drum unit clump the master top end, performing platemaking on the master with the thermal head. (In this machine, the master on the drum is ejected at the same time when platemaking is performed.) The master is conveyed to the drum unit via the platen roller and sponge roller1,2 by driving of the master feed stepping motor, while it is being processed in the head section. Sponge roller2 is driven through the master feed clutch (electromagnetic clutch), and controls the amount of master conveyed to the master clamp section of the drum unit with the master feed clutch ON / OFF. The end mark sensor starts to detect when the end mark (black) section printed on the end of the roll master is conveyed. "CHANGE MASTER" is displayed on the LCD panel. The end mark sensor also detects whether the master is conveyed properly through the sensor.

Cutter unit

Master feed clutch

Sponge roller 2

Master detection sensor

Master cover switch

Platen roller

Master cat

switch

Thermal head

Master feed stepping motorEnd mark sensor

1. Description

Platemaking / Master Feed Section

Platemaking / Master Feed section

Master Clump Opening /

Closing Section

Master Ejection Section

See page 54

See page 56

440315

440314

Thermal head up/down motor

Thermal head position sensor

Sponge roller 1

Master lead edge sensor

x Platemaking / Master Feed / Ejection Section

chap.2

2. Sequence of Operation

(1) Operation when the master set

Platen roller

Master lead edge sensor

Photo passing

Photo interrupting

Sponge roller 1Switch ON

440346

440347

When the master cover is closed, the platen roller and sponge roller1 rotate and feed out the document for 10 seconds.

When the master lead edge sensor is interrupted, the master is fed a few steps and stopped. If the master lead edge does not reach the master lead edge sensor, "MASTER SETTING ERROR" is displayed.

x Platemaking / Master Feed / Ejection Section

chap.2

Operation

When platemaking operation starts, the drum unit rotates to perform master removal process. The drum which has finished master removal process stops at the master set position.

Open the master clump. Sponge roller2 rotates with the master feeding clutch ON. A certain amount of the master tip end is fed to the master clump section and the sponge roller stops.

Open the master clump

After the master clump is closed and clump the master tip end, the drum rotates to roll up the master.

When the master bottom end reaches the top of the drum, master set is completed. Commence printing.

Master feeding clutch

Sponge roller 2

Master tip end

Master clump

Drum

Cutter

*Check the length of the master and

drum rotation angle to control the drum rotation.

*As the electromagnetic clutch is OFF,

the sponge roller is free.

(2) Platemaking / Master Feeding

63S00211

63S00212

63S00213

63S00214

292.6 0.1mm

x Platemaking / Master Feed / Ejection Section

chap.2

(1)Thermal Head

Description

The thermal elements are in alignment in the pel path direction, and are heated on the image section to make holes on the master film.

Specifications

Circuit

3. Functions of Parts

DC-DC PCB unit

CN2-1

-14

Main PCB unit

CN5-1

-24

CN4-1

-6

CN1-1

-6

Thermal head

No. Item DP-440

Picture element density

400DPI (15.7 dot/mm)

2 Effective memory width

440W07e

DP-340

400DPI (15.7 dot/mm)

260.1 0.1mm

DP-430

300DPI (11.81 dot/mm)

DP-330

300DPI (11.81 dot/mm)

260.2 0.2mm

x Platemaking / Master Feed / Ejection Section

chap.2

Exterior and Lot No.

Lot No.

Lot No. is shown with 4 digits including alphabet. Each digit has the following meanings. Serial No. in the production month Production month (See the table) Production year

Serial No. Serial No. in the production month Production month (See the table) Production year (Year of decade)

ABCDEFGHI JKL

Jan. Feb. Mar. Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec.

Sign

Month

NOTE :

Lot No.

Thermal resistor line

309 0.5(DP-440), 309 0.2(DP-430)

292.57 0.1(DP-440), 292.7 0.1(DP-430)

Signal connector

Pin (No.1)Pin (No.1)

Power connector

440349

440350

Thermistor

Label :DP-440 / DP-340 Label :DP-430 / DP-330

Lot No.

Label :DP-440 / DP-340

Label :DP-430 / DP-330

x Platemaking / Master Feed / Ejection Section

chap.2

NOTE :

440351

H-43 0100

0101 0101 0101 0101 0110 0110 0110

H-44 1011

1000 1001 1010 1011 1000 1001 1010

Lank

1 2 3 4 5 6 7 8

1822 - 1860 1861 - 1899 1900 - 1939 1940 - 1979 1980 - 2019 2020 - 2059 2060 - 2099

2100 - 2139 0110 1011 9 2140 - 2179 0111 1000 10 2180 - 2220 0111 1001 11 2221 - 2261 0111 1010 12 2262 - 2302 0111 1011 13 2303 - 2343 1000 1000 14 2344 - 2384 1000 1001 15 2385 - 2425 1000 1010 16 2426 - 2466

Lank

00 01 02 03 04 05 06 07

3825 - 3908 3909 - 3993 3994 - 4077 4078 - 4162 4163 - 4246 4247 - 4330 4331 - 4415

4416 - 4499 08 4500 - 4583 09 4584 - 4668 10 4669 - 4752 11 4753 - 4837 12 4838 - 4921 13 4922 - 5005 14 5006 - 5090 15 5091 - 5075

DP-440 / DP-340 DP-430 / DP-330

Resistance value

Resistance

Resistance value is described on the label. When the head is replaced and the HELP mode is initialized, set the DIP-SW (H-43,H-44) of the HELP mode.

HELP mode H-43,44 \ see p.263

Lank

Label :DP-440 / DP-340

Label :DP-430 / DP-330

Resistance valueLank

x Platemaking / Master Feed / Ejection Section

chap.2

End mark sensor PCB unit

CN4-4CN1-1

-3

-4

-7

-6

VR1

Blue

Red

Light green

Blue

Red

Light green

-2

-5

OrangeOrange

Main PCB unit

Reflection light amount

The larger the reflection light amount is, the smaller the output voltage is. The smaller the light amount is, the larger the output voltage is. The value is checked with the HELP 07.

* Adjustment of end mark PCB unit

Adjust the HELP mode H-07 so the difference between the maximum value of the black level and the white level becomes 20 or more.

HELP mode H-07 \ see p.228

Description

The end marks are located at a fixed distance relative to the master; as the master is being fed, the end mark sensor senses master condition and the end marks by means of intensity of reflected light.

(2) End Mark Sensor

End mark

End mark sensor

Circuit

23S0219

440W08e

2Value of the HELP mode H-07

Black level maximum

White level 5 Black level maximum - 20 or more

x Platemaking / Master Feed / Ejection Section

chap.2

1. Master Setting Error Detection

Operation

In platemaking, the end mark sensor uses amount of reflected light to detect presence or absence of a master on the transfer path. Then the following displays and operations are performed: 2When a master setting error is detected, "MASTER SETTING ERROR" is displayed and printing is not

processed.

2"MASTER SETTING ERROR" is only cleared by opening and closing the master cover.

(It is not cleared by turning the power off.)

2Printing is not performed but platemaking is only performed when the display is cleared after "MASTER

SETTING ERROR" is displayed. (Because the master is not attached to the drum.)

Timing

(1) While platemaking is being processed, the reflection light amount does not turn to be in a white level.

(Master detection sensor)

(2)

When platemaking process is finished (before printing process), the reflection light amount is in a white level.

MIN

MAX

HELP 07 Display value

Smaller

Larger

Reflection

light amount

White level top limit Black level maximun 20 or more

Black level top limit

Timing

When it is considered that the end mark is read under the following conditions, "CHANGE MASTER" is displayed.

q While the master is rolling up to the drum during platemaking, the following is checked. w When the master passes under the end mark sensor, the amount of reflected light is read. e If the following conditions are met, it is considered as master end.

Maximum Minimum 20 and Maximum white level top limit

2. Master End Detection

Operation

The end mark is printed on the area about 1 m from the end of the master.

2When the end mark is detected, "CHANGE MASTER" is displayed. 2When "CHANGE MASTER" is displayed, plate-making is not performed next.

(The display is not cleared by turning the power off.)

x Platemaking / Master Feed / Ejection Section

chap.2

Master lead edge sensor

Main PCB unit

Red

Blue

CN4-281 2 3

7 8 9

-30

Green

Red

Blue

Green

-29

Photopassing :0V Photointerrupting:5V

(3) Master Lead Edge Sensor

Reflection light amount

The larger the reflection light amount is, the smaller the output voltage is. The smaller the light amount is, the larger the output voltage is. The value is checked with the HELP 05.

Description

The master lead edge sensor is located at a fixed distance relative to the master. By means of reflected light, this sensor senses the presence of the master on the master travel path. If the intensity of the reflected light does not reach the "white" level (which indicates presence of the master) a single time during platemaking, "SET

MASTER ROLL PROPERLY" is displayed.

Circuit

HELP mode H-05 \ see p.224

440316

440W09e

Master lead edge sensor

Master

x Platemaking / Master Feed / Ejection Section

chap.2

440317

(4) Master Detection Sensor

Reflection light amount

The larger the reflection light amount is, the smaller the output voltage is. The smaller the light amount is, the larger the output voltage is. The value is checked with the HELP 07.

Description

The master detection sensor is located at a fixed distance relative to the drum. By means of reflected light, this sensor senses master setting errors. When a master setting error occurs, "MASTER SETTING ERROR" is displayed. While the master is not set to the drum, printing will not start even if the PRINT key is pressed. Instead, “CANNOT PRINT” is displayed.

Master detection sensor PCB

CN10-1CN1-1

-2

-3

-2

VR1

Red

Blue

Black

Main PCB unit

Circuit

HELP mode H-07 \ see p.229

Sensitivity adjustment of master detection sensor

Adjust variable resistor dial VR1 so that the difference between the black and white levels is 30 or more. Preferably, the value when master presence is sensed should be around 10.

Master detection sensor

440W10e

x Platemaking / Master Feed / Ejection Section

chap.2

Description

Completed, the stepping motor for platemaking and the drum stops temporarily, the cutter motor is turned on to drive the cutter and the master is cut.

CN1-1

-32

CN9-7

-8

Cutter motor(M5)

Black

Red

Black

Red

Drive PCB unit

CN3-1

-32

Main PCB unitDC-DC PCB unit

CN3-1

-12

CN3-1

-12

Circuit

(5) Cutter Unit

440W11e

x Platemaking / Master Feed / Ejection Section

chap.2

Operation

1) In the platemaking process, when the drum stops in the master winding position, the master

feeding clutch comes on, so that sponge roller2 is driven and feeds out the master by a fixed

amount.

2) The master clump opens and closes, to clump the master.

3) When the master is wound onto the drum, the master feed clutch turns off, leaving sponge roller2 free to be turned by the master as it is wound off the drum.

(6)

Master Feed Clutch(Electromagnetic clutch)

Description

Sponge roller2 is attached to the bottom section of the master conveyance way of the master feeding unit, and is driven via the master feeding clutch (CL1) by the platemaking motor. The rotation of sponge roller2 is controlled with the master feeding clutch ON / OFF.

CN1-1

-32

CN9-5

-6

Master feed clutch

Black

Drive PCB unit

CN3-1

-32

Main PCB unit

Circuit

63S00217

63S00218

63S00219

Master feeding clutch

Sponge roller 2

Master tip end

Master clump

Drum

B mode

C mode

B mode

23S0323E

x Platemaking / Master Feed / Ejection Section

chap.2

When the drum stops at the plate detachment position and the master clump which clumps the master tip end is opened (C mode), the pulling roller on the rolling section of the master ejection box pulls the master tip end into the box inside, and the master is rolled up to the core. If no core is installed, or when the master is fully wound onto the core, the core full switch (MS8) is mechanically actuated, and the message "CHANGE MASTER EJECTION CORE" appears on the LCD panel.

Blue

Brown

Black

Roll-up motor

Ejection box sensor

Master ejection sensor photo-emitting PCB

Master ejection box full switch

Master ejection sensor photo-receiving PCB

Gray

Pink

Blue

Yellow

Orange Orange

1 2

5 6

CN9-24

-25

-20

-21

-1

-2

-22

-23

Drive PCB unit

Main PCB unit

1 2

Red

Blue

CN20-41 2 3

-6

Pink

-5

Photopassing :0V Photointerrupting:5V

2. Circuit

1. Description

Master Ejection Section

Pulling roller

Plate detachment position

Master ejection sensor

photo-emitting PCB

Ejection box sensor

Master ejection box

full switch

Roll up motor

Master ejection sensor

photo-receiving PCB

440318

440W13e

Master ejection unit

Timing

If the variation in the amount of light received by the master ejection sensor during the making of 1 plate is less than a certain level (8 in the HELP06 display value), a plate ejection error is deemed to have occurred.

x Platemaking / Master Feed / Ejection Section

chap.2

2. Rotation Control of the Roll-up Motor

If the roll-up motor is kept rotating when the master tip end is pulled to the ejection box in the plate detachment process, the drum is actuated by the master and the stop position slips. To prevent this, the roll-up motor is stopped when the master is detected by the master ejection sensor. (If the master is not detected by the master ejection sensor, the Roll-up motor is stopped by the timer.)

(1) Master Ejection Sensor

Description

Photo-emission from the master ejection sensor is received on the master ejection sensor, and the sensor detects with the photo strength whether the master is pulled to the master ejection box. Photo-receiving amount is checked with the HELP06.

1. Master Ejection Error Detection

Operation

While one platemaking is being processed, the difference of photo-receiving amount is less than 8 by checking with the HELP5, which is determined as an master ejection error. The following display and operation are shown.

2"PLATE EJECTION ERROR" is displayed on the LCD panel and printing is not processed. 2"PLATE EJECTION ERROR" is cleared with the ALL CLEAR key , STOP key pressed. 2A master ejection error is not detected for one platemaking soon after a plate ejection error or master

setting error is detected.

¡If incorrect sensing occurs due to sensor malfunction, etc., HELP32can be used to

prohibit plate ejection error sensing.

IMPORTANT :

Smaller Larger

Photo-receiving amount

3. Function of Parts

HELP mode H-32 \ see p.254

HELP mode H-06 \ see p.226

HELP mode H-06 value

Value without master : the photo receiving amount of the master ejection sensor at the position where the first paper jam is detected after starting platemaking.

Threshold value

Threshold value : Value without master + 8

Time

x Platemaking / Master Feed / Ejection Section

chap.2

1) When platemaking starts, the drum unit rotates from the stop position to the opening / closing lever section (master removal position) and it stops temporarily. (B mode)

1. Description

The master clump on the drum unit is opened or closed by the two opening / closing levers' rotation operation. The opening / closing levers (one for the master set position, and the other for the master removal position) are on the master clump opening / closing section on the main body rear side. The master clump is opened or closed during platemaking. Opening / closing operation is as follows:-

5) Rotate the drum, to wind the master onto it.

4) Open and close the master clump to have it grip the leading edge of the used master.

3) Close the master clump, rotate the drum again and stop the drum at the next opening / closing lever section (master set position).

2) Open the master clump to have the used master tip end gripped by the plate ejection unit.

Master Clump Opening / Closing Section

Master clump opening / closing lever

(Master set position)

Master clump opening /

closing section

440319

Master clump opening / closing lever

(Master removal position)

x Platemaking / Master Feed / Ejection Section

chap.2

The following is the structure of the master clump opening / closing section viewed with the rear cover opened. The rotation stop position of the master clump opening / closing lever is determined by the clump motor and two cams. There are 3 rotation stop positions: A mode, B mode and C mode. Their functions are as follows:-

(1) Structure

2. Operation of Master Clump Open / Close Lever

The drawing below is a section through the machine's interior, viewed from the control side.

Master clump opening / closing lever

Master clump opening / closing section

2A mode 2B mode 2C mode

Clump motor

B mode adjusting cam

Master set position

Drum

Master removal position

A / C mode adjusting cam

B mode sensor

A / C mode sensor

Master clump opening / closing lever

Master clump

23S0266

x Platemaking / Master Feed / Ejection Section

chap.2

(2)

Master Set / Removal Operation

The drum rotates to the master removal position Stop

The drum rotates to the master set position Stop

x Platemaking / Master Feed / Ejection Section

chap.2

(3) Clump Opening / Closing Lever

Position (A / B / C Mode)

Mode Photointerrupter stop position / state of sensor

Functions

In the normal state or during printing, the master clump opening / closing lever turns out from the master clump opening / closing lever.

o d e

The master clump opening / closing lever pinch the master clump opening / closing arm.

The master clump is open. This state occurs when the master is set or removal.

B mode sensor

(PS4)

B mode sensor

(PS4)

B mode sensor

(PS4)

A / C mode sensor (PS3)

A / C mode sensor

(PS3)

Photointerrupting

gPh

oto-passing

Photopassing

Photo-

interrupting

Photopassing

Photointerrupting

Photo-interrupting

Photopassing

x Platemaking / Master Feed / Ejection Section

chap.2

The mode is detected under the following conditions

2A mode

When the B mode sensor (PS4) is photointerrupted, the A / C mode sensor (PS3) detects the edge of photointerrupting fphotopasing.

*With the power ON, the A mode is determined when the B mode sensor is in the photointerrupting state

and the A/C mode sensor is in the photopassing state. If not in the A mode with the power ON, the

master clump opening / closing lever rotates to the B mode and stops. When the lever stops at the

B mode, the drum rotates with the drum rotation switch and returns to the A mode at the stop position.

2B mode

When the A/C mode sensor is photointerrupted, the B mode sensor detects the edge of photointerrupting / /photopassing or photopassing - photointerrupting.

2C mode

When the B mode sensor is photopassing, the A/C mode sensor detects the edge of photointerrupting

photopassing.

(1) A / B / C Mode Sensor

B mode detection sensor(PS4)

Main PCB unit

Red

Blue

-91 2 3

-11

Green

-10

A/C mode detection sensor(PS3)

Red

Blue

CN17-31 2 3

-5

Orange

-4

CN1-1

-32

CN9-26

-27

Clump motor(M3)

Yellow

Orange

Drive PCB unit

CN3-1

-32

Photopassing :0V Photointerrupting:5V

Circuit

Operation / Sequence

3. Function of Parts

440W14e

x Platemaking / Master Feed / Ejection Section

chap.2

Returning Operation Flowchart When the Power Is Cut Off Accidentally

The machine returns to the initial state automatically when the power is turned off mistakenly during processing platemaking, master removal and master set simultaneously or when the power returns after it is interrupted.

Power ON

Master removal / set process

"PLEASE WAIT" display

Set / removal operation continues

"PLATE EJECTION ERROR"

displayed?

Open the scanner

Remove the mis-set master

Close the scanner

Standby

Initial desplay

Is the state the same as the previous state (before the power is turned OFF)?

Process other than removal / set

"PLEASE WAIT" lights out

Power ON

yes

c Paper Feed Section

chap.2

1. Description

Feeding of the paper is performed by the paper separator (employing the center separation method) and paper feed roller (there is no corner finger). Elevation of the feed tray is powered by the elevator motor.The paper lead edge sensor is equipped at the rear of the paper feed roller. When the paper does not reach the paper lead edge sensor or the signal sensor during the preliminary feeding, “PAPER JAM ON THE LEFT SIDE” appears. Paper fed by the paper separator and paper feed roller is fed further by the timing roller and guide roller to the point where its leading edge is sandwiched between the drum and the press roller. Then the pression of the timing roller and guide roller is released (by moving the guide roller upward several mm), so that the paper is fed through at a speed equal to the circumferential speed of the drum and press roller. The press roller sensor senses the paper feed condition; if a feed error occurs, the message “PAPER JAM ON THE FEEDER SIDE” is

displayed.

For details, see “1.Paper Jam Detection Timing” in chapter 2 (n Paper ejection section).

\See page 90

cPaper Feed Section

(Signal solenoid)

440301

Paper separator

Paper feed roller

Elevator motor

Feed traySupplemental paper tray

Timing roller

Press roller

Guide roller

P-roller sensor

LPU

(Long Paper Unit)

Paper detection sensor

Elevator top limit sensor

Elevator bottom

limit switch

Paper feed stepping motor

Printing position

adjusting unit

Paper lead edge sensor

Double feed detection sensor

c Paper Feed Section

chap.2

Timing roller

Paper feed segment

Timing segment

Pinion gear

Paper feed roller

When the main motor turns, the paper feed cam rotates, causing the paper feed segment and timing segment to execute the reciprocating motion shown below, which turns the pinion gear.

2. Operation

(1) Rotation of the Paper Feed Roller and

Timing Roller

440302

Paper feed cam

c Paper Feed Section

chap.2

The paper feed roller is driven by the paper feed stepping motor via the timing belt. The rotational timing is controlled by the program.

(2) Paper Feed Roller Drive

Paper feed roller

Paper feed stepping motor

Timing belt

440303

c Paper Feed Section

chap.2

Timing roller is actuated to rotate by the pinion gear and spring clutch. When the paper feed cam rotates, the reciprocating motion of the timing roller segment is transmitted to the pinion gear, and the spring clutch works to rotate the Timing roller in the direction of conveyance.

(3) Driving of the Timing Roller

Timing roller

Paper feed cam

Spring clutch

Pinion gear

Paper feed segment

440304

Paper lead edge sensor

Double feed detection sensor

c Paper Feed Section

chap.2

440305

After the Press roller is pressed to the drum, the printing paper is gripped firmly with the drum and Press roller, the Guide roller is released from the Timing roller. This is called "escaped". Escape timing is within a period when the printing paper is conveyed about 10 mm after it is gripped with the drum and Press roller.

(4) Escape the Guide Roller

¡When the timing is too late, the printing paper is gripped at two places too long. Thus

master elongation and slippage occur.

¡On the contrary, when the timing is too early, the printing paper is not gripped at all, and it

is not well settled. Thus creasing of paper and dispersion of the printing position occurs.

IMPORTANT :

Escape cam

Timing roller

Guide roller sensor

Press roller

Guide roller

Paper

Drum

about

10mm

about

10mm

Guide roller motor

c Paper Feed Section

chap.2

The “paper feed length” is the length by which the paper feed roller feeds out the print paper. When the paper feed roller feeds out the print paper, the guide roller is pressed against the timing roller and does not rotate; as a result, the paper arches up between the paper separator and the timing roller, since the distance between these two items is only 80mm, while the length by which the paper is fed out from the paper feed roller is 95mm. This arching has the effect of correcting any skewing of the paper (as the leading edge is held firm between the guide and timing rollers). It also has the effect of lessening the load on the timing roller when it feeds the paper through, thus minimizing slippage. For feed amount, the leading edge of the paper is detected by the paper feed length sensor and paper feed is controlled by program( HELP mode H-86,88 ).

HELP mode H-86,88 \ see p.294,296

¡If paper feed length is too large: the arching dimension will be too large, and if the paper is

of a very stiff type, it will buckle up between the paper feed roller and the paper feed inlet (upper), causing a PAPER JAM error ("PAPER JAM ON THE FEEDER SIDE").

¡If paper feed length is too small: the arching dimension will be too small, so that arching

will be unable to correct skewing of the paper, and skewing and wrinkling will be liable to occur. Furthermore, the slippage that occurs when the timing roller feeds the paper through will be very large, resulting in printing position errors.

IMPORTANT :

(5) Paper Feed Length

Cam follower

Paper feed cam

Paper feed roller

Guide roller

Paper separator

Timing roller

440306

Paper lead edge sensor

Double feed detection sensor

c Paper Feed Section

chap.2

The printing position is adjusted by changing the timing of the paper toward the drum with the

PRINTING POSITION key on the control panel.

Description

When the PRINTING POSITION key on the control panel is pressed, the link cam is driven by the motor. As the link cam moves, the cam follower position (bearing) from the paper feed cam changes. Accordingly drive timing for the timing roller can be changed.

2Press the key ;

Cam follower moves in the direction of : e Drive timing of the timing roller becomes earlier.

Paper timing becomes earlier, and the picture image moves backward.

2Press the key ;

Cam follower moves in the direction of : b Drive timing of the timing roller becomes later.

Paper timing becomes later, and the picture image moves forward.

(1)

Printing Position Adjusting Mechanism

Pressing makes cam follow-

er move in the bdirection

Pressing makes cam follow-

er move in the edirection

Timing roller

Link cam

Printing position motor

Paper feed cam

Cam follower

440307

3. Functions of parts

ADJUST

PRINT POS.

Top / bottom

center sensor

Top / bottom

encoder sensor

440352e

c Paper Feed Section

chap.2

Top/bottom center sensor

Main PCB unit

Red

Blue

-291 2 3

-31

White

-30

CN1-1

-32

CN9-3

-4

Top/bottom motor(M6)

Orange

Yellow

Drive PCB unit

Photopassing :0V Photointerrupting:5V

Top/bottom encoder sensor

Red

Blue

CN20-11 2 3

-3

Black

-2

Photopassing :0V Photointerrupting:5V

Circuit

Operation

Top and bottom limit of print position is detected by the top/bottom encoder sensor and the center sensor. The center position is detected by the standard position sensor. The top/bottom encoder sensor detects the top/bottom motor rotation. The main PCB unit controls the number of top/bottom motor rotations with the top/bottom encoder sensor signal.

Operation with the Power ON

The printing position returns to the standard position by operating with the power ON, depending on the sensor state as follows.

When positioned between the standard position

and the bottom limit:

Rotate the printing position motor normally (CW)

to return the printing position to the standard.

When positioned between the standard position

and the top limit:

Rotate the printing position motor reversely (CCW) to return the printing position to the standard.

Top/bottom center sensor

Printing position

Top/bottom encorder sensor

Bottom limit Standard Top limit

: Photointerrupting : Photopassing

440W15e

440353e

c Paper Feed Section

chap.2

Description

Circuits

Double feed detection sensor

photo-receiving PCB

(2) Double Feed Detection Mechanism

The double feed detection sensor is mounted at the rear of the paper lead edge sensor to detect feeding of multiple papers. When it is detected, “DOUBLE FEEDING ERROR” is displayed on the LCD. If double feeding occurs with the tape cluster (optional) equipped, the tape is inserted.

440W32e

440354

Blue

CN4-1

-2

Main PCB unit

Drive PCB unit

Main PCB unit

Light green

-8

CN8-7

Glay

Blue

Paper lead edge sensor photo-emitting PCB

Double feed detected sensor photo-receiving PCB

-10

CN8-9

White

Blue

Signal sensor photo-emitting PCB

-6

CN4-5

Blue

Pink

Blue

CN8-11

-12

Orange

Signal sensor photo-receiving PCB

Blue

CN4-2

-3

Yellow

Paper lead edge sensor photo-receiving PCB

Double feed detected sensor photo-emitting PCB

Double feed detection sensor

photo-emitting PCB

Paper lead edge sensor

photo-receiving PCB

Paper lead edge sensor

photo-emitting PCB

c Paper Feed Section

chap.2

(3)

Elevator Top Limit Sensor

Description

Circuits

Operation

The elevator top limit sensor senses decrease of the paper pile, and the top limit position of the feed tray.

It does so by detecting the up/down motion of the paper feed shaft.

Sensing of feed tray top limit

2When the feed tray rises, the paper in it presses the paper feed roller upward, making the paper feed shaft

lever (photointerrupter) rotate upwards about its fulcrum, until it no longer obstructs the sensor’s light beam. Restoration of the sensor’s light beam signals that the paper tray has reached the top limit, and triggers stopping of the feed tray’s rise.

Sensing of paper decrease

2As printing progresses and the paper decreases, the paper feed roller gradually descends, until it obstructs

the sensor’s light beam. When this happens, the feed tray is raised until the light beam is restored.

If the light beam is not restored within about 30 seconds of the sending of the RAISE FEED TRAY command, error E002 (elevator lock) is displayed.

Elevator top limit sensor(PS9)

Red

Blue

CN4-221

2 3

3 4 5

-24

Light green

Red

Blue

Light green

-23

Main PCB unit

Photopassing :0V Photointerrupting:5V

440W16

440311

Paper feed roller

Elevator top limit sensor

Paper

Paper feed shaft lever Elevator top limit sensor

Paper

c Paper Feed Section

chap.2

(4)

Elevator bottom Limit Switch

Description

Circuits

Operation

This is a micro switch that senses the bottom limit position of the feed tray.

When the feed tray rises, the bracket disengages from the switch and the switch closes. When the feed tray descends to its bottom limit position, the bracket engages the switch’s actuator, opening the switch. If the switch does not open within about 30 seconds of the sending of the LOWER FEED TRAY command, error

E002 (elevator lock) is displayed.

Elevator bottom limit switch descent(push):OPEN

Light blue

CN4-20

-21

Main PCB unit

440W17e

Elevator motor

Actuator

440312

Elevator bottom

limit switch

2Bottom limit position

Gear

c Paper Feed Section

chap.2

When there is no paper :

When there is paper placed :

(5) Paper Detection Sensor

Description

Circuits

Operation

Senses presence/absence of paper in the feed tray. When the paper in the tray runs out, the message "ADD PAPER" is displayed and printing stops.

When there is no paper, the sensor is in the state of photopassing(open). When paper is placed inside, the sensor is in the state of photointerrupting(close). When an absence of paper is detected, the message "ADD PAPER" is displayed on the LCD panel.

2When absence of paper is sensed, platemaking, printing and test printing are not possible. 2If the paper runs out during printing, "ADD PAPER" is displayed on the LCD panel, printing is stopped,

and the feed tray descends to its lower limit position.

2If the paper runs out during platemaking, operation continues until the end of the platemaking process,

then operation stops (without proceeding to the printing process), and the feed tray descends to its lower limit position.

Paper detection sensor

paper present : CLOSE paper absent : OPEN

Red

Blue

CN4-251 2 3

6 7 8

-27

Purple

Red

Blue

Purple

-26

Main PCB unit

Photopassing :0V Photointerrupting:5V

440313

440W18e

Photointerrupting

Photopassing

Paper

Paper detection sensor

c Paper Feed Section

chap.2

(6) Long Paper Unit Mechanism (Option)

Circuits

Brown

White

G - roller motor

CN9-1

-2

Drive PCB unit

G - roller

sensor

Red

Blue

CN9-28

1 2 3

-30

Yellow

-29

Photopassing :0V Photointerrupting:5V

440W33e

Description

With the LPU unit equipped, duration the timing roller and the guide roller are detached from each other is extended (the guide roller is lifted by a few millimeters), thus the paper with the maximum length of 540 mm can be fed through.

v Drum Driving Section

chap.2

vDrum Driving Section

1. Description

Main motor encoder sensor

Encoder

Main motor

Drum gear

Drum stop / JAM detection position sensor

Drum position cam

440320

Master set / removal

position sensor

v Drum Driving Section

chap.2

440322

Drum position cam

(1) Drum Stop / JAM Detection Position

Sensor

2. Function of Parts

The drum stop / JAM detection position sensor detects the drum stop position and JAM detection position. 2The drum stop position is the position where the drum stops at the same time when a beep sounds after the

JOG switch (drum rotation switch) is kept pressing.

2The JAM detection position is the timing to check paper jamming in the paper ejection section. 2Paper jamming in the paper ejection section is checked in the above timing with the jam sensor (photo-

receiving) and P roll sensor.

Operation

The drum stop / JAM detection position sensor is positioned while the drum is rotating as follows:-

2The drum stop position is detected with the edge of photointerrupting / photopassing. 2The JAM detection position is detected with the edge of photopassing / photointerrupting.

Drum stop/JAM detection position sensor(P5)

Red

Blue

CN17-61

2 3

-8

Yellow

-7

Main PCB unit

Photopassing :0V Photointerrupting:5V

Circuit

440W19e

Drum stop/JAM detection position sensor

JAM detection

position

JAM detection

position

Drum stop

position

Drum stop

position

Drum stop/JAM detection

position edge

Drum stop/JAM detection

position sensor

JAM detection position edge

v Drum Driving Section

chap.2

(2) Master Set / Removal Position Sensor

The master set / removal position sensor detects the drum stop position when the plate is attached or detached. It also detects the speed reducing timing for stopping at the printing speed and for pressing the

JOG switch (drum rotation

switch).

Operation

The following is the state of the master set / removal position sensor while the drum is rotating.

2The master detachment position is detected with the edge of photopassing fphotointerrupting. 2The master set position is detected with the edge of photointerruptingfpotopassing. 2The drum speed is reduced to the slow (before-stop) speed at the master removal position before the drum

stops.

Master set/removal position sensor(PS6)

Red

Blue

CN17-121 2 3

-14

Purple

-13

Main PCB unit

Photopassing :0V Photointerrupting:5V

Circuit

440W20e

Master set/removal position sensor

Master removal

position

Master set

position

Master removal

position

Master set

position

440321

Drum position cam

Master removal position edge

Master set position edge

Master set / removal

position sensor

v Drum Driving Section

chap.2

Description

The drum rotates as long as the JOG switch (drum rotation switch) is pressed (within one rotation) and stops at the stop position with a beep.

When the drum stops there, the LED mounted on the JOG switch 1 will light up.

In the normal state, the drum rotates (within one rotation) when the JOG switch (drum rotation switch) is kept pressed and the drum stops at the stop position, reducing the speed to the slow (before-stop) speed at the first master removal position. When the P-roller sensor is in the photopassing state (P-roller ON) at the first plate detachment position, the drum passes the stop position without reducing the speed.

Drum rotation 1 switch

Drum rotation 2 switch

Purple

CN4-8

-9

Light green

CN21-5

-6

Main PCB unit

Circuit

(3)

JOG Switch 1,2 (Drum Rotation Switch 1,2)

JOG switch

(Drum rotation switch)

JOG switch (drum rotation switch) (SW3)

440355

440W21e

2When the JOG Switch (Drum Rotation Switch) Is

Pressed Down

Sequence of Operation

Drum stop/JAM detection position sensor

Master removal position

Master set position

Drum stop position

JAM detection position

Master removal position : drum reduce the speed

Drum stop position : drum stops

Master set/removal position sensor Main motor P-roller sensor

When the P-roller sensor is in the photopassing state(P-roller ON), the drum dose not reduce the speed at the master removal position.

JOG switch

(Drum rotation switch)

v Drum Driving Section

chap.2

(4) Control of the Main Motor

Main motor encoder sensor(PS7)

DC24V

Main motor(M1)

Main motor PCB unit

Main PCB unit

Red

Blue

Red

Brown Brown

Blue Blue

Blue

CN1-1

CN4-1

-2

-3

-4

CN5-1

-2

1 2 3

-3

Gray

-2

Main 4

Main 3

Main 2

Main 1

Inter lock monitor

Encoder dividing

+5V

GND

CN3-1CN15-21

-22

-23

-24

-25

-26

-27

-28

-2

-3-4-5

-6-7-8

Blue

Red

Orange

White

Black

Gray

Light blue

Purple

Terminal plate(+24)

Terminal plate(GND)

Circuit

440W22e

v Drum Driving Section

chap.2

1. Rotation Speed Control by Encoder Sensor

The encoder sensor detects the main motor rotation. The main motor PCB Unit controls the number of main motor rotations with the encoder sensor signal. The encoder sensor signal is transmitted to the main PCB Unit as encoder dividing signal (8 dividings). The number of main motor rotations is checked with the HELP01.

2. Selecting the Speed

The speed is selected with the main 1 - 4 on the main PCB Unit. The following are the speed depending on the pin state.

Slow 2 is applied to accelerating only. it is not used to reduce the speed. All the speeds including slow 1 are accelerating speeds. if the slow 1 is not operated, all the other speeds are not operated.

IMPORTANT :

STOP

Pre-stop 1 Pre-stop 2

JOG

1st

SPEED

2nd

SPEED

3rd

SPEED

4th

SPEED

5th

SPEED

CN 15-25 Main 1

L H L H L H L H

-26 Main 2

L L H H L L H H

-27 Main 3

L L L L H H H H

-28 Main 4 H L L L L L L L L

HELP mode H-01 \ see p.217

b Press Section

chap.2

bPress Section

1. Description

(1) Press Roller Timing & Printing Area

Description

In this machine, the master is rolled up to the drum, ink is transferred to the drum and the printing paper is pressed to the drum by the press roller to print. Printing is performed on only the sections that meet the following requirements.

1) The sections of the master on which holes are made by processing platemaking. (platemaking area)

2) The hole sections of the drum.

3) The section of the drum pressed with the press roller. (the area pressed ON)

When the pressed-on position is 0 under the normally adjusted conditions, relations among 1), 2) and 3) are as follows*-

Drum gear

Press roller

Press lever

P-roller sensor

(mm)

DP-440/430

428 438 423

Press ON length Drum hole section length Printing area length

440308

Center of the master clump shaft

Bottom end of the hole section

Cam

Paper

Cancel lever

Signal solenoid

Contact pressure unit

42315

( mm )

Cancel lever

DP-340/330

370 370 355

: 438 : 370

DP-340/330

DP-440/430

: 423 : 355 Printing area

DP-340/330

DP-440/430

: 428 : 370 Press area

DP-340/330

DP-440/430

: 310

: 270

DP-340/330

DP-440/430

b Press Section

chap.2

The press roller is ON (the press roller is pressed to the drum) or OFF by operating the press lever up and down with the cam inside the drum gear.

Press roller : OFF Press roller : ON

Do not press off later than the hole section end position since ink seeps from the bottom end of the master.

IMPORTANT :

Adjusting the printing area means that the cam curve goes up and down as shown in the figure. The timing of drum ON / OFF varies depending on the cam curve`s up and down. The ON position is before the drum hole section, so the printing area is not influenced. (Do not shorten the printing area length as it is influenced.) The OFF position is only changed and the printing area is adjusted.

P-roller sensor

Cam

Press roller

Press lever

440309

Press OFF position Press ON position

Drum hole section

end

Drum hole section

start

Printing area

Cancel lever

Signal solenoid

: 423mm : 355mm

DP-340/330

DP-440/430

b Press Section

chap.2

(1) P- roller Sensor

The P- roller sensor detects up and down of the press roller. The press roller only ascends when the paper is fed from the paper feed section by the cancel lever. The P- roller sensor also is used to know whether the paper is fed.

Operation

The P- roller sensor position varies depending on the press roller position as follows:-

• When the press roller is OFF (DOWN) : photointerrupting

• When the press roller is ON (UP) : photopassing

P-roller sensor(PS8)

Main PCB unit

Red

Blue

CN17-151 2 3

-17

Light blue

-16

Photopassing :0V Photointerrupting:5V

Circuit

2. Function of Parts

440W23e

Press roller : OFF Press roller : ON

Cam

Press roller

Press lever

440309

P-roller sensor

Cancel lever

Signal solenoid

b Press Section

chap.2

(2) Switching the Contact Pressure

The contact pressure can be switched on the operation panel. When it is changed on the operation panel, the contact motor will start up to effect the switch as soon as the PRINT key is pressed.

Circuits

Brown

Purple

Pressure motor

Pressure center switch

Green Green

1 2

CN12-8

-9

CN21-1

-2

Drive PCB unit

Main PCB unit

Pressure position switch

White White

3 4

-3

-4

Pressure encoder sensor

Red

Blue

CN12-10

1 2 3

-12

Orange

-11

Photopassing :0V Photointerrupting:5V

Press roller

Pressure center switch

Pressure motor

Pressure encoder sensor

Pressure position switch

440310

440W24e

b Press Section

chap.2

2Low contact pressure position:

Sensed by pressure center switch. Switch turns from OFF to ON in response to movement in the direction of the arrow.

2Standard contact pressure position:

Sensed by pressure center switch. Switch turns from OFF to ON in response to movement in the direction of arrow 1. Switch turns from ON to OFF in response to movement in the direction of arrow 2.

2Hi contact pressure position:

Sensed by pressure position switch. Switch turns from ON to OFF in response to movement in the direction of arrow1. Switch turns from OFF to ON in response to movement in the direction of arrow2.

1. Contact pressure position sensing

1 2

440362

440363

440364

Pressure position switch

Pressure center switch

Drum unit

Press roller

n Paper Ejection Section

chap.2

nPaper Ejection Section

1. Description

In the paper ejection section the printed paper is removed from the drum and is ejected to the print tray.

Escape cam

Paper stripper finger

Paper ejection motor

Top blow fan

440323

Paper ejection fan

Eject fan encoder sensor

Paper ejection JAM

sensor(Photo-emitting)

Paper ejection JAM

sensor(Photo-receiving)

Paper ejection fan unit

Top blow fan unit

n Paper Ejection Section

chap.2

2. Functions of Parts

Mechanical Structure and Operation

In addition to the paper stripper finger installed in the center, there are two sub paper remover fingers on both sides. There is an air diffuser on the tip of the finger. Compressed air transmitted from the air pump is blowed out of this hole to detach the tip end of the paper from the drum.

To remove the paper from the drum firmly, the gap between the tip of finger and the drum surface and between the tip of finger and the corner of the master clump are adjusted as follows:-

Air pump

Sub paper stripper finger

Paper stripper finger

Sub paper stripper finger

Drum

surface

Approx

0.5mm

Paper stripper

finger

(1) Paper Stripper Finger

440325

440324

n Paper Ejection Section

chap.2

-3

-4

Top brow fan 2

Red

Black

CN10-1

-2

Top brow fan 1

Red

Black

Drive PCB unit

Operation

During printing, the fan blows a constant stream of air at the paper stripper finger, from the rear. This assists paper stripping and also presses the paper against the ejection belt, which stabilizes ejection.

Top blow fan

Paper stripper finger

Circuit

(2) Top Blow Fan

440W26e

440328

Top blow fan unit

Top blow fan 2

Top blow fan 1

n Paper Ejection Section

chap.2

Description

The JAM sensor photo-receiving element is installed on the paper ejection fan unit and detects whether the paper is ejected normally. When it is detected that the paper is not ejected normally, "PAPER JAM ON THE

EJECTION SIDE" is displayed on the LCD panel.

Operation

The JAM photo-emitting PCB is installed in the top blow fan, and the photo-receiving PCB in the paper ejection fan unit. HIGH with the optical path interrupted. LOW with the optical path passing. There are two cases of interruption; interrupted by the paper and the top blow fan is open.

Circuit

(3) Paper Ejection JAM Sensor

440W25e

440326

Paper ejection JAM

sensor(Photo-emitting)

Paper ejection JAM sensor(Photo-receiving)

Paper ejection JAM sensor photo-emitting PCB

Blue

CN17-24

Yellow

-25

Paper ejection JAM sensor photo-receiving PCB

Gray

Blue

CN17-18

-19

Main PCB unit

n Paper Ejection Section

chap.2

2Paper jamming on the ejection side

JAM1: The bottom end of the paper is not ejected.

When the JAM sensor (light-emitting and light-receiving) is interrupted at the timing of JAM detection

position edge (photopassing \ photointerrupting) of the drum stop / JAM detection position sensor PS5.

JAM2: The tip end of the paper is not ejected.

When the JAM sensor is not interrupted at all while the P-roller sensor is in the state of photopassing

(pressed ON).

JAM (stop): When the JAM sensor is interrupted as the top blow fan unit is open when the machine stops.

The display is cleared when the sensor is in the state of photopassing.

2Paper jamming on the feeder side

JAM3:

The paper does not pass the signal sensor though the paper is fed. The P-roller sensor is not in the state

of photopassing when the drum rotates twice after the paper feed is ordered ON.

1. Paper Jam Detection Timing Description

Paper jamming is divided into two types: "PAPER JAM ON THE EJECTION SIDE" and "PAPER JAM ON THE FEEDER SIDE". Paper jamming is detected under the following conditions. When paper jamming is detected, "PAPER JAM" is displayed on the LCD panel, and the machine stops printing operation. The display is cleared by removing the cause of paper jam and pressing the STOP key or by restarting printing.

Sequence of Operation

440327

Paper ejection JAM

sensor(Photo-emitting)

P-roller sensor

Master set/removal position sensor

Paper ejection JAM

sensor(Photo-receiving)

Drum stop/JAM detection position sensor

Master set/removal position sensor

P-roller sensor

Paper ejection JAM sensor

Drum stop position sensor

JAM detection position sensor

Drum stop

Drum stopJAM

A4 B4 A3

A4 LG B4

DP-440 / DP-430 DP-340 / DP-330

Bottom end of paper

Sensor photointerrupted Sensor photopassing

JAM

A4 B4 A3 A4 LG B4

n Paper Ejection Section

chap.2

2nd speed

190rpm

130rpm

150rpm

165rpm

5th speed

Description

The paper ejection belt takes the paper stripped off the drum by the paper stripper finger to the print tray. The belt is driven by the paper ejection motor. Its speed is sensed by an eject fan encoder sensor.

1. Paper ejection belt speed

The paper ejection belt is controlled to the speed that matches the printing speed. The belt speeds that are set for the various printing speeds are shown in the table below. The set speeds can be adjusted using HELP01.

Eject fan encoder sensor

Red

Blue

CN2-11 2 3

-3

White

-2

CN7-1

-2

Paper ejection motor

Black

Red

CN10-5

-6

Paper ejection fan

Red

Black

Drive PCB unit

Photopassing :0V Photointerrupting:5V

Printing speed

Paper ejection belt speed

3rd speed

4th speed

225rpm

1st speed

(4) Paper Ejection Belt

Circuit

Eject fan encoder sensor

Paper ejection motor

Paper ejection belt

HELP mode H-01 \ see p.220

440329

440W27e

n Paper Ejection Section

chap.2

(5) Paper aligning mechanism

Description

Paper can be aligned neatly by considering the ejection angle. Adjustments should be made in accordance with paper thickness.

For thinner paper: Set the lever in the upper position. For thicker paper: Set the lever in the lower position.

* Although the lever is usually set at the intermediate position for paper of normal thickness (65g/m2), the

lever position should be adjusted depending on the condition of the paper.

Lever

Thinner paper

Ticker paper

440330

Normal(65g/ )

m Drum Section

chap.2

mDrum Section

The ink control section is in the drum unit. The ink control section is supplied with ink in the ink pack attached to the drum unit by the motor. The ink control section has an ink detection function, and is always supplied with a fixed amount of ink. Printing darkness is adjusted by changing the gap between the squeegee roller and the ink roller. Five color inks are available: black, red, blue, green and brown. Perform color printing to replace the drum unit for each color. (Press the drum rotation switch to the drum home position to replace the drum unit.) In this machine, whether there is a drum or not is detected. If the drum is not attached properly, it is taken as "NO DRUM", and "NO DRUM" is displayed on the LCD panel.

Ink detection PCB unit

Ink motor

Master clump

Squeegee roller

Ink roller

1. Description

440331

Ink roller up/down motor

Ink roller up/down sensor

Ink pump

Drum limit sensor

Drum center sensor

Drum shift motor

Drum detection switch

m Drum Section

chap.2

Green

Brown

Ink roller motor

CN12-1

-2

Drive PCB unit

Main PCB unit

Blue

-3

Brown

-4

Black

-5

Brown

White

Ink roller up/down motor

CN14-7

-8

Pink Blue

Drum shift motor

-3

-4

Yellow

-5

White

-6

Light green

-2

Black

CN14-1

6 2 5

+23V

Ink detection PCB unit

CN1-3

-1

-2

Drum limit sensor

Red

Blue

CN21- 71 2 3

- 9

Glay

- 8

2 4 4

Photopassing :0V Photointerrupting:5V

Drum center sensor

Red

Blue

1 2

-12

White

-11

5 17 7

Photopassing :0V Photointerrupting:5V

Ink roller up/down sensor

Red

Blue

1 2 3

-15

Purple

-14

-10

-13

2 7 10

Photopassing :0V Photointerrupting:5V

2. Circuit

440W28e

m Drum Section

chap.2

Description

The ink amount variation in the ink control section is read by the electric capacity variation between the detection needles on the ink detection PCB Unit and the GND and the ink signal is output to the main PCB Unit. The main PCB Unit controls the motor ON and OFF by this signal. When NO INK continues while the drum rotates 20 times (the number of drum unit rotations; it varies depending on the printing speed.*) during printing, it is determined that the ink pack is empty, "CHANGE

INK" is displayed and the machine stops printing.

(1) Ink Detection

3. Function of Parts

\See page 97

440332

Ink detection PCB unit

LED

Squeegee roller

Ink roller

Ink

Detection needle

m Drum Section

chap.2

2Timing of the LED and the ink motor operation is

as follows. The ink motor works during printing (driving output signal).

Ink detection PCB unit

LED CN1-2

No ink Light out +5V

Ink Light up 0V

2Ink detection PCB unit

Between the CN12-3 and GND

1. LED Display and Output Signal on the Ink Detection PCB Unit

2When the electric capacity variation between the

detection needles on the ink detection PCB Unit and GND is over the threshold value, the LED on the ink detection PCB Unit lights up and the ink signal (0V) is output.

m Drum Section

chap.2

2. "CHANGE INK" Display Timing

When HIGH (5V) is output by detecting ink while the drum continues to rotate 20 times (the number of rotations varies depending on the printing speed.*) during printing, it is detected that the ink pack is empty, "CHANGE INK" is displayed on the error display, and printing stops. At the same time the power for the ink motor is turned off.

*The drum rotates until "CHANGE INK" is displayed after HIGH is output from the ink detection PCB unit

during printing. The number of drum rotations varies depending on the printing speed as follows:-

Printing speed

Number of rotations

4526838041005120

Drive PCB unit Output CN12-5

m Drum Section

chap.2

Description

At times other than printing, the ink roller is separated from the inner surface of the drum by a fixed clearance. During printing, however, the press roller rises and presses the ink roller into contact with the drum inner surface, so that ink is supplied via the drum inner surface to the printing paper. This mechanism prevents ink from being supplied to the drum inner surface if the printer is run without any paper. When the master is detached in the platemaking process, ink on the drum surface is removed along with the document, which means that in the first printing after the master is attached, there is a possibility of insufficient ink on the drum surface, resulting in faint images. To prevent such ink insufficiency when in the first printing, the machine is equipped with a mechanism for raising and lowering the ink roller. Before paper is fed in, this mechanism pushes the ink roller against the drum inner surface, so that ink is forcibly supplied immediately prior to the start of printing. As a result, the images on the first sheet printed after platemaking are sufficiently bold. Ink roller up and down operations are included as elements in the Fine Start mode, together with contact pressure adjustment, and therefore are optimally controlled in accordance with room temperature, length of time out of use, number of sheets in last run, etc.

Ink roller up/down sensor

Red

Blue

CN21-131 2 3

-15

Purple

-14

CN1-1

-32

CN14-7

-8

Ink roller up/down motor

Brown

White

Drove PCB unit

CN3-1

-32

2 7 10

Main PCB unit

Photopassing :0V Photointerrupting:5V

Circuit

(2) Ink Roller Up/Down Mechanism

440W29e

m Drum Section

chap.2

¡Standby position during printing

Cam is in the bottom position, and the ink roller is raised up by a spring. The ink roller up/down sensor is in the state of photopassing(OPEN), signalling that the ink roller has reached the upper limit position. In this position, the ink roller is not touching the drum inner surface.

¡Ink roller descent

The motor turns, and cam pushes the ink roller downward. When edge plate rotates, the ink roller up/down sensor is in the state of photointerrupting (CLOSED), the sensor signals that the roller has reached the bottom limit position, and the motor stops. In this position, the ink roller is pressed against the drum inner surface, and ink will be supplied even if the machine performs printing without paper.

¡Ink roller ascent (to standby position)

The motor turns, and when cam reaches the bottom position, the spring raises the ink roller up. When the ink roller up/down sensor is in the state of photopassing, the sensor signals that the roller is in the raised position, and the motor stops.

Operation

Ink roller up / down motor

Ink roller up / down sensor

Cam

Spring

440357

440358

440359

440360

Spring

Edge plate

Ink roller

Ink roller up / down sensor

Drum inner surface

Edge plate

Cam

Ink roller up / down motor

Ink roller

Photopassing

Drum inner

surface

Photopassing

Photointerrupting

100

m Drum Section

chap.2

Description

The ink control section in the drum is supplied with ink in the ink pack by driving the ink motor.

Operation

The piston performs suction and release operation by moving up and down.

When the piston moves up, it draws ink from the ink pack into the pump.

When the piston moves down, the pump releases ink.

Mechanical Structure

(3) Ink Pump

440333

440334 440335

Ink motor Ink pump

101

m Drum Section

chap.2

Description

The drum switch detects whether the drum is installed to the machine. When it is detected that there is no drum installed, "NO DRUM" is displayed on the error LCD panel the machine stops operation. When no drum is detected during operation, all the operations stops emergently.

Operation

When the drum is attached to the main body, the cam unit covers the pin and is locked firmly. The difference of the cam unit prevents the cam unit from being loosened due to the machine vibration. When the pin is at the bottom of the cam unit difference, the drum SW is open as shown in the figure. When the pin is over the cam unit difference, the drum SW is closed.

Drum detection switch

No drum : CLOSE Drum installed : OPEN

Main PCB unit

White

CN4-10

-11

No drum : 0V Drum installed : 5V

Circuit

(4)Drum Detection Switch

Lever

Switch OFF

Cam unit

440336

2No drum2Drum installed

440W30e

Switch ON

102

m Drum Section

chap.2

(5) Fine Start Mode

This mode automatically sets optimum values for the following start conditions: timing of ink roller actuation during platemaking, number of no-paper rotations with the ink roller actuated, and contact pressure at printing start. These optimum settings are based on room temperature, the length of time the printer was out of use, and the number of prints last time it was used. They ensure clear printing right from the first sheet after platemaking.

*Room temperature of 10; or below can cause insufficient ink supply, even in Fine Start Mode.

Standby state The cam turns a half-revolution, so that the ink

roller is pressed against the drum inner surface. Then the drum rotates.

The cam turns a half-revolution, so that the ink roller moves out of contact with the drum inner surface.

Printing begins.

Cam

Ink

Roller

Screw

Motor

Drum

Ink roller

Press roller

Spring

Squeegee roller

Operation

103

m Drum Section

chap.2

(6) Drum Shift Mechanism

Description

The printing position (left and right) can be switched automatically via the operation panel. If the position is changed via the operation panel, the drum shift motor starts moving by turning the PRINT key on.

Operation

Shifting amount of the printing position in the pel path direction is detected by combining the drum center sensor and the drum limit sensor to detect the standard position by using the drum center senor.

* Operation during plate making

The following operations are performed by pressing the PLATEMAKING key. When the drum shift motor is rotated clockwise (CW), the drum is shifted from the drum home position to the plate making position (opposite from the control). After master setting, the drum is returned to the drum home position by rotating the drum shift motor counterclockwise (CCW).

Drive PCB unit

Main PCB unit

Pink Blue

Drum shift motor

-3

-4

Yellow

-5

White

-6

Light green

-2

Black

CN14-1

6 2 5

Drum limit sensor

Red

Blue

CN21- 71 2 3

- 9

Glay

- 8

131516 3

2 4 4

Photopassing :0V Photointerrupting:5V

Drum center sensor

Red

Blue

1 2 3

-12

White

-11

46 5 6 6

5 17 7

Photopassing :0V Photointerrupting:5V

-10

Circuit

Sensor

440W34e

Drum limit sensor

440361

Drum center sensor

Drum shift motor

Duplo DUPRINTER DP-440, DUPRINTER DP-430, DUPRINTER DP-340, DUPRINTER DP-330 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

D Using the service manual

Safety instructions

1. Cautions regarding the installation location

2. Cautions for installation work

3. Cautions for maintenance, inspection and servicing

DLocations of warning stickers

Table of Contents

Chapter 1 Introduction

Chapter 2 Description of the Operation

Platemaking / Master Feed Section

Master Ejection Section

Master Clump Opening / Closing Section