This service manual is only intended for engineers trained in service ...... Two
hours before machine operation, set a timer and start operating the air condition-
...... For 4.5 mm: Adjust using a 4 mm hex- agonal wrench and a 15 cm scale. .....
Enter the Drum screen. → Select Servo (ON) and press OK. OK. ESC. 3100.
NEXT.
Plate Thermal Recorder
4300
SER VICE MANUAL SERVICE PT-R4300/PT-R4000II/PT-R4000
2002 06-06
Ver1.1
2002 05-23
Ver1.0
Quality Promotion Department Media Technology Company
For your safety Caution labels are affixed to potentially hazardous parts or areas of the equipment for the safety of the operators and maintenance staff. Caution labels are classified into two types "WARNING" and "CAUTION" depending upon the degree of potential danger as shown below. Please read, understand and heed the meanings of these labels to prote yourself and to prevent unforeseen accidents. :
Indicates a potentially hazardous situation which, if not avoided or properly handled, could possibly result in death or serious injury.
:
Indicates a potentially hazardous situation which, if not avoided or properly handled, could possibly result in minor or moderate injury or equipment damage.
The PT-R4XXX operators must thoroughly read this manual. Do not turn on the machine’s power supply until all of the precautions have been read and understood. Very serious accidents may occur if this instruction is not observed.
Please keep the following premises and expectations in mind. This service manual is only intended for engineers trained in service procedures and maintenance personnel trained by qualified engineers. Readers are therefore expected to already appreciate the potential hazards presented by this equipment and type of work, as well as understand all the basic operations needed for equipment maintenance. When exporting the machine International transfer of this equipment, any of its parts, components and/or software must be carried out in compliance with the relevant laws and ordinances of the country of export and the country of equipment end-use. We do not assume any responsibility or liability for equipment transferred without regard to proper export/import regulations or procedures. Limits of responsibility Please note that equipment specifications are subject to change without notice for updates and improvements. This may cause inconsistencies between the contents of this manual and the equipment you currently possess. We shall not be held responsible for any damage caused by conditions beyond our control such as customer modification, disassembly or misuse of our products, programs or software, or their use in a defective or deficient environment. Although great care has been taken in preparing this manual, if you find that certain points seem unclear or in error, please contact Dainippon Screen Mfg. Co., Ltd. We assume no responsibility or liability for any damage or consequential and/or indirect losses resulting from any accident or malfunction that might occur during the operation of this equipment. Copyright ©1999-2002: Dainippon Screen Mfg. Co., Ltd. The copyright for this entire manual belongs to Dainippon Screen Mfg. Co., Ltd. Copying, reprinting or reproduction of this manual in whole or in part in any media without our express consent infringes upon the copyright and the rights of the publisher.
Contents
§ On safety 1. On Safety .................................................................................................................................. § -1 1-1. When using the PT-R4XXX .............................................................................................. § -1 1-2. Precautions for electricity ................................................................................................ § -2 1-3. Precautions for equipment operation ............................................................................... § -8 1-4. Maintenance .................................................................................................................... § -9 1-5. Caution labels on the equipment ................................................................................... § -10 1-6. Using the laser safety .................................................................................................... § -14 1-7. Precautions during transport and installation ................................................................. § -18
A. Outline 1. Introduction ................................................................................................................................ A-1 1-1. For maintenance personnel .............................................................................................. A-1 1-2. Laser maintenance and safety ......................................................................................... A-3 1-3. Basic information .............................................................................................................. A-4 2. System overview ........................................................................................................................ A-7 2-1. System setup diagram ...................................................................................................... A-7 2-2. Recommended configurations .......................................................................................... A-7 3. Overall configuration chart and part names ............................................................................... A-8 3-1. Front view of the main unit ................................................................................................ A-8 3-2. Back view of the main unit ................................................................................................ A-8 3-3. Plate conveyor view of the main unit ................................................................................. A-9 3-4. Peripheral device connectors ........................................................................................... A-9 3-5. Inside of front cover ........................................................................................................ A-10 3-6. Inside of rear cover ......................................................................................................... A-10 4. Electrical wiring ........................................................................................................................ A-11 4-1. Block diagram ................................................................................................................. A-11 4-2. Function of board ........................................................................................................... A-12 5. Specifications .......................................................................................................................... A-14 5-1. Basic specifications ........................................................................................................ A-14 6. Comparison of PT-R4300, PT-R4000 and PT-R4000II .............................................................. A-16 7. Restriction of the plate size for the PT-R4300/4000/4000II ....................................................... A-21
B. Installation 1. Installation ................................................................................................................................. B-1 1-1. Information required for adjustments during installation .................................................... B-1 1-2. Installation schedule ......................................................................................................... B-2 2. Installation conditions ................................................................................................................. B-3 2-1. Dimensions of delivery path ............................................................................................. B-3 2-2. Dimensions when delivering the machine ......................................................................... B-4 2-3. Dimensions when the machine is installed ....................................................................... B-7 2-4. Installation space and layout position ............................................................................. B-13 2-5. Environmental conditions ............................................................................................... B-18 2-5-1. Temperature and humidity ....................................................................................... B-18 2-5-2. Floor load capacity .................................................................................................. B-19 2-5-3. Floor levelness ........................................................................................................ B-19 2-5-4. Vibrations ................................................................................................................ B-19 PT-R4300 SERVICE MANUAL
i
Contents 2-5-5. Room cleanliness .................................................................................................... B-19 2-6. Power requirements ....................................................................................................... B-20 2-7. Cable and hose lengths .................................................................................................. B-21 3. About transportation ................................................................................................................ B-22 3-1. Transporting the main unit using 1a forklift (or similar equipment) .................................. B-22 3-2. Transporting the main unit by hoisting it .......................................................................... B-22 4. Installation procedure ............................................................................................................... B-23 4-1. Packing list check ........................................................................................................... B-23 4-2. Assembly........................................................................................................................ B-23 4-2-1. Installation of the PT-R4300 ..................................................................................... B-23 4-2-2. Removing the transport fixing brackets ................................................................... B-24 4-2-3. Adjusting the levelness ............................................................................................ B-32 4-3. Connection ..................................................................................................................... B-33 4-3-1. Connecting the blower hose and gas suction hose .................................................. B-33 4-3-2. Connecting the blower unit control cable ................................................................. B-34 4-3-3. Connecting an auto loader to the PT-R4300(option) ................................................ B-37 4-4. Start of the machine ....................................................................................................... B-40 4-5. Initial settings ................................................................................................................. B-42 4-5-1. Outline for panel settings ......................................................................................... B-42 4-5-2. Setting the media type ............................................................................................. B-43 4-5-3. Setting the plate ...................................................................................................... B-47 4-5-4. Setting the printing machine information ................................................................. B-50 4-5-5. Setting the exposure conditions ............................................................................... B-55 4-6. Operation check and adjustment .................................................................................... B-57 4-6-1. Checking the registration ......................................................................................... B-57 4-6-2. Confirming plate winding and exposure ................................................................... B-61 4-6-3. Laser calibration ...................................................................................................... B-66 4-7. Exposure adjustment ...................................................................................................... B-67 4-7-1. Adjusting the focus value ......................................................................................... B-68 4-7-2. Adjusting the zoom value ........................................................................................ B-71 4-7-3. Adjusting the light intensity ................................................................. B-74 4-7-4. Saving the data ....................................................................................................... B-75 4-7-5. Test exposure .......................................................................................................... B-76 4-7-6. Other test exposure methods .................................................................................. B-80 4-8. Other settings ................................................................................................................. B-83 4-8-1. Setting the exposure maintenance .......................................................................... B-83 4-8-2. User settings ........................................................................................................... B-85 4-9. Exposure check .............................................................................................................. B-97 5. Punch attachment(option) ........................................................................................................ B-98 5-1. Attachment ..................................................................................................................... B-98 5-2. Setting the punch name (Service menu) ...................................................................... B-100 5-3. Setting the punch name (Main menu) ........................................................................... B-102 5-4. Tilt correction method ................................................................................................... B-104 6. Relocation .............................................................................................................................. B-106 7. Installation check sheet .......................................................................................................... B-111
C. Replacement & Adjustment 1. Main belt replacement ............................................................................................................... C-1 ii
PT-R4300 SERVICE MANUAL
Contents 2. Encoder replacement ................................................................................................................ C-4 3. Adjusting the automatic balancer weight detection sensors ...................................................... C-7 4. Removing the trailing edge clamps ........................................................................................... C-9 5. Attaching the trailing edge clamps .......................................................................................... C-10 6. Replacement procedure for the trailing edge clamp arm drive motor(M20) ............................. C-13 7. Adjusting the trailing edge clamp arm origin and end sensors ................................................ C-15 8. Adjusting the leading edge clamp open/close sensors ............................................................ C-18 9. Replacement and adjustment procedure for the plate side edge detection sensors for side alignment(PH61H, PH61A) ................................................................................................. C-20 10. Adjusting the trailing edge clamp hook sensor ...................................................................... C-26 11. Adjusting the hook lever switch ............................................................................................. C-29 12. Sensor for detecting an interleaf on the back of the plate(PH51) .......................................... C-31 13. Replacement and adjustment procedure for the plate top side detection sensors (PH29H,PH29A) ................................................................................................................ C-32 14. Replacement and adjustment procedure for the drum vacuum pressure sensor(P1) ............ C-35 15. Replacement and adjustment procedure for the plate sensor(PH6) (2 plate wind, or float)(Ser.No.-100) .................................................................................... C-36 16. Balancer weight replacement procedure ............................................................................... C-40 17. Balancer motor unit replacement procedure ......................................................................... C-41 18. Balancer sensor replacement procedure .............................................................................. C-41 19. Path driving motor replacement procedure ........................................................................... C-42 20. Squeeze roller height adjustment .......................................................................................... C-43 21. Loading Guide (1) Replacement and Adjustment .................................................................. C-46 22. PT-R4300 Ball screw for Sub-scanning Replacement Procedure .......................................... C-48 23. Countermeasure against registration deviation in PT-R4300 ................................................. C-53 24. Countermeasures for Registration Deviation on PT-R4300(additional information) ............... C-62 25. Procedure for replacing the PT-R4XXX transfer path spring .................................................. C-65 26. Procedure for replacing the LD block .................................................................................... C-68 27. Procedure for replacing and adjusting the power supply ....................................................... C-71 28. Procedure for replacing and adjusting the pulse motor driver ............................................... C-71 29. Procedure for replacing the AC servo driver(E1A) ................................................................ C-73 30. Procedure for replacing and setting the inverter (U8) for the suction blower ......................... C-74 31. Plocedure for replacing the RCP2 board ............................................................................... C-77
D. Operation panel 1. Screen flow diagram (PT-R4000:Ver) ........................................................................................ D-1 1-1. Main menu (when PT-R8600 is used independently) ....................................................... D-1 1-2. Main menu (when SA-L/MA-L is connected) ................................................................... D-4 1-3. Service menu .................................................................................................................. D-5 2. Startup of the main unit without performing initialization ......................................................... D-10 3. Detailed descriptions of the Service/Maintenance screens ..................................................... D-11 3-1. How to enter the Service/Maintenance Menu screen .................................................... D-11 3-2. Service/Maintenance Menu screens ............................................................................. D-12 3-3. Sensor Test screens ...................................................................................................... D-14 3-4. Actuator Test screens .................................................................................................... D-19 3-5. Drum Test screens ........................................................................................................ D-24 3-6. Pulse Motor Test screens .............................................................................................. D-26
PT-R4300 SERVICE MANUAL
iii
Contents 3-7. Recording Head Unit Test screens ................................................................................ D-29 3-7-1. Zero Return screen for recording head unit/focus motor/zoom motor ..................... D-31 3-7-2. Positioning screens for recording head unit/focus motor/zoom motor ..................... D-32 3-7-3. Peltier Test screen .................................................................................................. D-33 3-7-4. Laser Calibration screen ........................................................................................ D-34 3-7-5. LD ON screen ........................................................................................................ D-36 3-7-6. Calibration Position screen ..................................................................................... D-38 3-7-7. Moving to Calibration Position screen ..................................................................... D-39 3-7-8. Temperature Display screen ................................................................................... D-40 3-7-9. Laser Power Measurement and Cable Disconnection Check screen ...................... D-41 3-7-10. Iop/-Iop screen ....................................................................................................... D-44 3-8. Input Parameter screen ................................................................................................. D-45 3-8-1. Correction Data Setting screens ............................................................................. D-47 3-8-2. Preset Plate Type Setting screen ............................................................................ D-49 3-8-3. Drum Base Position Setting screen ........................................................................ D-50 3-8-4. Drum Position Setting screen ................................................................................. D-52 3-8-5. Punch Adjustment screen ...................................................................................... D-54 3-8-6. Calibration Sensor Position Adjustment screen ...................................................... D-55 3-8-7. Punch Data Setting screen ..................................................................................... D-56 3-8-8. Recording Head Parameter Setting screens .......................................................... D-57 3-8-9. Drum Parameters Input screen .............................................................................. D-73 3-8-10. Miscellaneous Data Setting screen ........................................................................ D-80 3-8-11. Recording Head Data Control screen ..................................................................... D-81 3-8-12. Clamp Weight Setting screen ................................................................................. D-82 3-8-13. Cassette Data Setting screen ................................................................................. D-83 3-8-14. Password Setting screen ........................................................................................ D-86 3-9. Machine Option Selecting screen .................................................................................. D-87 3-10. I/O Reading and Writing screen ..................................................................................... D-88 3-11. Initialization screens ...................................................................................................... D-89 3-11-1. Data initialization .................................................................................................... D-90 3-11-2. Brand Name Selection screen ................................................................................ D-91 3-11-3. Consumable Timer screen ..................................................................................... D-92 3-12. Special Action screen .................................................................................................... D-94 3-12-1. Machine Initialization screen .................................................................................. D-95 3-12-2. Pickup Clamp, Trailing Edge Clamp Attachment screen ......................................... D-96 3-12-3. ORG-EZ Check screen .......................................................................................... D-97 3-12-4. Front Sensor Offset screen .................................................................................... D-98 3-12-5. Centering Test screen ............................................................................................. D-99 3-12-6. Adjust Displacement Sensor screen ...................................................................... D-100 3-12-7. NVRAM Backup screen .........................................................................................D-101 3-12-8. NVRAM Data Restore screen ............................................................................... D-102 3-12-5. Register Test screen .............................................................................................. D-103 3-13. Special Action 2 screens .............................................................................................. D-104 3-13-1. Machine Initialization screen .................................................................................D-105 3-13-2. Balancer Testing screen ........................................................................................ D-106 3-13-3. Mail Testing screen ................................................................................................D-107 3-13-4. Auto Loader Testing screen ...................................................................................D-108 3-13-5. Plate Pad Unit Testing screen ................................................................................D-110 iv
PT-R4300 SERVICE MANUAL
Contents 3-13-6. Interleaf Pad Unit Testing screen ...........................................................................D-111 3-13-7. Multi Auto Loader Testing screen ...........................................................................D-112
E. Reference 1. Sequence explanations (PT-R4300) .......................................................................................... E-1 1-1. Initialization sequence ...................................................................................................... E-1 1-2. Main processing of initializing ........................................................................................... E-3 1-3. Processing of trans pass initializing .................................................................................. E-4 1-4. Processing of punch sequence ........................................................................................ E-5 1-5. Processing of winding sequence ...................................................................................... E-6 1-6. Discharge sequence ........................................................................................................ E-8 1-7. Drumhigh speed rotating sequence ................................................................................ E-10 1-8. Auto Balance sequence .................................................................................................. E-11 2. Sequence explanations (PT-R4000II) ...................................................................................... E-12 2-1. Initialization sequence .................................................................................................... E-12 2-2. Main processing of initializing ......................................................................................... E-14 2-3. Processing of trans pass initializing ................................................................................ E-15 2-4. Processing of punch sequence ...................................................................................... E-16 2-5. Processing of winding sequence .................................................................................... E-17 2-6. Discharge sequence ...................................................................................................... E-19 2-7. Drumhigh speed rotating sequence ................................................................................ E-21 2-8. Auto Balance sequence .................................................................................................. E-22 3. Parts layout and sensor position .............................................................................................. E-23 3-1. Front side of main unit .................................................................................................... E-23 3-2. Back side of main unit .................................................................................................... E-25 3-3. Left side of main unit ...................................................................................................... E-27 3-4. Rite side of main unit ...................................................................................................... E-29 3-5. Top side of main unit ....................................................................................................... E-31 3-6. Transport unit of main unit .............................................................................................. E-33 3-7. Plate side alignment of main unit .................................................................................... E-34 3-8. Clamp arm unit of main unit ............................................................................................ E-34 3-9. Recording Head unit ....................................................................................................... E-35 3-10. RCP2 board ................................................................................................................... E-36 3-11. RB31 board .................................................................................................................... E-38 3-12. SPX32 board .................................................................................................................. E-39 3-13. PIO-PTR4(2) board ........................................................................................................ E-40 3-14. con-ptr4 board ................................................................................................................ E-44 3-15. Laser Head CPU board .................................................................................................. E-47 3-16. Laser Head Driver board ................................................................................................ E-48 3-17. Laser Head Mother board .............................................................................................. E-49 3-18. Laser Head Relay board ................................................................................................. E-50 3-19. Laser Diode Array Block ................................................................................................. E-52 4. Maintenance software RMLight4 .............................................................................................. E-53 4-1. Outline ............................................................................................................................ E-53 4-2. Requirements ................................................................................................................. E-53 4-3. Terminal setting .............................................................................................................. E-54 4-4. Installation of RMLight4 .................................................................................................. E-54 4-5. Connecting the terminal to the main unit ........................................................................ E-54 PT-R4300 SERVICE MANUAL
v
Contents 4-6. Procedure for downloading the PT-R firmware ............................................................... E-55 4-7. Procedure for downloading the PT-R panel data ............................................................. E-58 4-8. Uploading or downloading the PT-R’s machine specific value data ................................. E-61 4-8-1. Data types that can be uploaded or downloaded ..................................................... E-61 4-8-2. Procedure for data upload ....................................................................................... E-63 4-8-3. Procedure for data download ................................................................................... E-66 5. Power supplies and interlocks .................................................................................................. E-69
F. Error list 1. Error list (PT-R4300 : Ver.1.00) ................................................................................................... F-1 2. Error list (PT-R4000 : Ver.3.0X , PT-R4000II : Ver4.0X)) ............................................................ F-18
G. Supplement 1. Punch List ................................................................................................................................ G-1 2. Recommend parts list ............................................................................................................ G-12
vi
PT-R4300 SERVICE MANUAL
§ On safety
§ On Safety
1. On Safety 1-1.When using the PT-R4XXX
• The following descriptions of safety precautions and operating procedures are intended solely for the benefit of operators and other personnel using the PT-R4XXX for its originally intended purposes. • The intended purposes and usage of the PT-R4XXX are those described in Introductory Note. We shall not be held liable or responsible for any damage, losses or malfunctions caused by using or operating this machine in ways other than those described in this manual. • To the best of our knowledge, the various parameters and data presented in this manual are reliable under the conditions described. However, we shall not be held legally responsible for the accuracy or relevance of this information. Furthermore, we assume no responsibility or liability for any damage or consequential and/or indirect losses resulting from any accident or malfunction that might occur during the operation of the PTR4XXX. • The PT-R4XXX was designed and manufactured with special attention to safety considerations. However, it is impossible either to eliminate all potential sources of danger from such products or to anticipate all possible hazards and misuses. It is therefore critical that you both familiarize yourself, all your operators and other relevant personnel with all of the noted precautions, countermeasures and related procedures, and take maximum care when operating the PT-R4XXX.
PT-R4300 SERVICE MANUAL
§ -1
§ On Safety 1-2.Precautions for electricity
1)
Power supply • Before connecting the PT-R4XXX power cable to your switchboard, be sure to confirm that the power supply switch is turned OFF. • When the PT-R4300 is installed overseas, perform proper grounding in accordance with the regulations of the country of installation. • If the power for the entire unit cannot be supplied, connect an exclusive ground wire for the auto loader. • The PT-R4XXX incorporates high-voltage circuits. Touching any part of your body to such circuits can cause serious injury and even death. BE EXTREMELY CAREFUL not to touch these circuits, especially with wet hands. • Whenever you install the PT-R4XXX in Japan, be sure to use the power cable provided with it. • Power cables are not provided for machines to be shipped abroad. Depending on the country of installation, be sure to use a power cable which can handle AC300V or an equivalent rated voltage and has 3 cable leads of at least 2.0 mm2. • However, if the diameter of each wire rod is 4 mm or larger, the power supply cable cannot be connected to the power connecting section of the PT-R4300.
2)
Switching operation of power supply • Before turning ON the power supply switch to the PT-R4XXX, be sure to confirm the following: 1) The accessories (e.g. supply cassette) are properly mounted and connection areas (e.g. supply unit) are connected properly and securely. 2) Doors are completely closed, and covers are attached properly. • Be sure to turn OFF the power supply and fix the power supply switch using a padlock etc. before you start maintenance, cleaning or repairs. Switching the power switch to “ I ” turns the power ON and switching it to “ O ” turns the power OFF.
§ -2
PT-R4300 SERVICE MANUAL
§ On Safety
ON
ON
PT-R4300
OFF
OFF
ON
Power supply switch
OFF
ON
OFF
Power supply switch PT-R4000/PT-R4000II
PT-R4300 SERVICE MANUAL
§ -3
§ On Safety 3)
Power cables • If you find anything that might indicate power cable damage such as unusual deformations or surface flaws, immediately turn OFF the power switch and the circuit breaker of the switchboard, and contact our nearest dealer or branch office. • Do not place heavy objects or articles with sharp edges anywhere on the power cable or forcefully pull at it.
PT-R4300
4)
Processing after power failures • When a power failure in external electric power occurs, immediately turn OFF the circuit breaker of the switchboard and the power switch of the PT-R4XXX. • If a power failure, which is caused by a utility defect, occurs while the safety interlock release key is being used, turn OFF the switchboard breaker of the user’s site. • Since the PT-R4300 is reset in concurrence with shutdown of the power supply, turn ON the switchboard breaker, which has been turned OFF, and perform a normal initialization after the power has been restored. • Be sure that nobody is touching the machine when you perform initialization with the safety interlock release key ON.
§ -4
PT-R4300 SERVICE MANUAL
§ On Safety 5)
Interlocks • To ensure operator safety, the PT-R4XXX is provided with a variety of interlocking safety devices. Do not deactivate these devices except when service engineers are performing maintenance. Operating the PT-R4XXX when these safety devices are inactive could result in severe injury and/or damage to the equipment. • If a cover is opened during exposure, the respective rollers stop automatically. Always wait at least five seconds until the rollers come to a complete stop before touching them. • Turning ON the safety interlock release key shuts down the power supply to the laser. However, be aware that power is still supplied to the moving parts.
While these doors are open, releasing interlocks or performing control or adjustment procedures other than those specified in this manual will cause dangerous laser radiation exposure. Door switch Door interlock switch
PT-R4300
Front cover interlock switch Door switch
PT-R4000/PT-R4000II
Front cover interlock switch Door interlock switch PT-R4300 SERVICE MANUAL
§ -5
§ On Safety
Drum slow-down software switch
Back side cover interlock switch
PT-R4000/PT-R4000II
Right side cover interlock switch
PT-R4000/PT-R4000II
§ -6
PT-R4300 SERVICE MANUAL
§ On Safety 6)
Forced drum stop switch • The PT-R4XXX is equipped with a forced drum stop switch that allows you to stop the rotation of the drum in an emergency.
Do not use this switch during normal operation. this switch is only to be used if the duum needed to be stopped in case of an emergency.
Forced drum stop switch
(PT-R4000,PT-R4000II,PT-R4300)
PT-R4300 SERVICE MANUAL
§ -7
§ On Safety 1-3.Precautions for equipment operation
• Do not turn on the PT-R4XXX’s power supply or start operation until this manual has been thoroughly read and fully understood. • All operators must wear appropriate work clothing.
Wear clothing that will not become caught in the machinery.
Hands are wet. Long hair is tied back. Cuffs are open. A necktie or necklace is dangling. Cuffs are buttoned.
Safety boots are recommended.
Unneeded things are carried. Excessively long pants. Slippers or sandals.
• Whenever you notice anything abnormal, report it immediately to your supervisor or manager so appropriate measures can be taken quickly. • The PT-R4XXX cannot be guaranteed to operate continuously without an operator in attendance. In order to immediately deal with emergencies, an operator trained for initial corrective action should always be in attendance. • Training courses for Dainippon Screen’s products are provided at any time at the nearest Dainippon Screen Technical Center. We recommend that all users of the PT-R4XXX receive proper training before using the equipment. Please contact our branch office or the dealer for an application for the training courses. • When the PT-R4XXX0 is not operated for a long period of time, be sure to turn OFF the circuit breaker of the switchboard. • During operation, do not open any protective covers attached to the equipment. Opening these covers may be hazardous to the safety of operators and other persons working in the vicinity, and may also hinder the equipment’s normal functioning. • Never allow open flames, spark sources, etc. in the vicinity of the PT-R4XXX. • Do not operate the PT-R4XXX if you feel in any way sick, nauseous or unsteady.
§ -8
PT-R4300 SERVICE MANUAL
§ On Safety 1-4.Maintenance
• Maintenance must always be performed by specially trained and authorized maintenance engineers. • Never turn the machine’s power on while maintenance engineers are working on the equipment.
PT-R4300 SERVICE MANUAL
§ -9
§ On Safety 1-5.Caution labels on the equipment
• Caution labels are attached to potentially hazardous parts or areas of this machine for the safety of the operators and maintenance staff. • Be sure to observe the following precautions when you perform operation or maintenance of the PT-R4XXX. • Be sure to follow the instructions on these labels. • If a label has faded or fallen off, replace it immediately with a new one. • Do not peel or tear off labels or erase their markings. • For replacement labels, contact your nearest Dainippon Screen dealer or branch office. • Do not block the visibility of labels by covering or placing anything in front of them. Label indicating the power supply specifications of the PT-R4XXX.
(PT-R4000,PT-R4000II,PT-R4300)
Label indicating that the PT-R4XXX complies with CDRH Regulations. (for U.S.A. only)
§ -10
PT-R4300 SERVICE MANUAL
§ On Safety
Label indicating that the PT-R4XXX is a Class 1 laser product.
(PT-R4000,PT-R4000II,PT-R4300)
Label indicating that the PT-R4XXX complies with FCC and VCCIRules.
(PT-R4000,PT-R4000II,PT-R4300)
Label indicating that the PT-R4XXX complies with CE standards.
(PT-R4000,PT-R4000II,PT-R4300)
PT-R4300 SERVICE MANUAL
§ -11
§ On Safety Label indicating the class, power, and wavelength of laser beam. (n/ a in USA)
(PT-R4000,PT-R4000II,PT-R4300)
Label indicating that this unit contains laser radiation.
(PT-R4000,PT-R4000II,PT-R4300)
Label showing the location of an ground terminal.
(PT-R4000,PT-R4000II,PT-R4300)
Label indicating the technical classification of the laser head (for U.S.A. only).
(PT-R4000,PT-R4000II,PT-R4300)
§ -12
PT-R4300 SERVICE MANUAL
§ On Safety Label calling attention to a nearby laser aperture.
(PT-R4000,PT-R4000II,PT-R4300)
Label warning that opening this cover may expose you to dangerous laser radiation.
(PT-R4000,PT-R4000II,PT-R4300)
Label warning that this equipment contains a high leakage current and mustbe grounded.
(PT-R4000,PT-R4000II,PT-R4300)
PT-R4300 SERVICE MANUAL
§ -13
§ On Safety 1-6.Using the laser safety Notices concerning the safe use of the unit. These must be following to avoid injuries and accidents.
1)
LASER SAFETY This PT-R4XXX is certified as a Class4 laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. This means that the recorder does not produce hazardous laser radiation. Since radiation emitted inside the PT-R4XXX is completely confined with in protective housings and external covers. The laser beam can not escape from the machine during any phase of user operation.
2)
CDRH REGULATIONS The Center for Devices and Radiological Heanh (CDRH) of the U.S. Food and Drug Adminstration implemented regulations for laser pfoducts on August 2.1976.These regulations apply to laser products manufactured from August1. 1976. Compliance is mandatory for products marketed in the United States. The label shown in the figure indicates compliance with the CDRH regulations and must be attached to laser products marketed in the United States. Ordinafy operation will not release laser radiation into the work environment. Do not remove any of the safety covers for this product or release any of its interlock switches. Laser radiation may cause injuries to your body (e. g. weakened eyesight, skin cancer).
3)
For European model PT-R4XXX is classified as a CLASS1 LASER PRODUCT in accordance with IEC Pub 1. 1 825 1984. Ordinary operation will not release laser radiation into the work environment. Do not remove any of the safey covers for this product or release any of its interlock switches. Laser radiation may cause injuries to your body (e. g. weakened eyesight, skin cancer).
§ -14
PT-R4300 SERVICE MANUAL
§ On Safety • INTERNAL LASER REGULATIONS Max. radiation power------------------------------32W Wavelength---------------------------------------830nm The rating for the semi-conductor laser is 1W X32 pieces and is classified as Class 1. • You will not be exposed to laser beam radiation during ordinary operation. • If the doors shown in the figure below are opened, the interlock switches located in the respective positions (six places) are activated to intercept laser beams.
PT-R4300 SERVICE MANUAL
§ -15
§ On Safety
§ -16
PT-R4300 SERVICE MANUAL
§ On Safety
PT-R4300 SERVICE MANUAL
§ -17
§ On Safety 1-7.Precautions during transport and installation
1)
Transport and installation The PT-R4XXX’s transport and installation must always be handled by engineers and contractors authorized by Dainippon Screen. We shall bear no responsibility whatever for any equipment breakage, damage or malfunctions caused by or during transport or installation performed by anyone other than the above specified personnel. Whenever the PT-R4XXX must moved, transferred or re-installed, please entrust all procedures to our nearest branch office or dealer. (See list at the end of this manual.)
2)
Installation environment Installing the equipment in the following locations may cause machine damage or malfunctions. Do not install the machine anywhere that is exposed or subject to: • direct sunlight; • electrical interference such as voltage fluctuations or line noise; • sudden, drastic temperature changes; • a nearby heat source; • high temperature and/or humidity (adequate temperature:21°C to 25°C (73.4°F ± 3.6), adequate humidity: 40 to 70 %RH); • excessive dirt, grime or dust; • strong and/or persistent vibration; • dew condensation; • nearby flame or spark sources; • corrosive chemical vapors, mists or gasses; • limsy or uneven flooring.
High Temperature and humidity
§ -18
Vibration
PT-R4300 SERVICE MANUAL
§ On Safety 3)
Grounding connection • Be sure to connect the ground line before connecting the power supply, since leakage current is over 3.5 mA in the PT-R4XXX. • To help prevent electric shocks, be sure to independently ground the AC outlet in the specified manner (grounding resistance: 100Ω or less). Wire the power separately from other equipment. • The cable connecting the machine to the outlet should have sufficient capacity to prevent voltage drops in either the steadystate current or the starting current. To forestall other possible problems in the PT-R4XXX’s electrical system, always use fuses and circuit breakers that match its specifications. Please ask your electrical contractor or authorized personnel to help select appropriate parts and wiring configurations. • When the PT-R4300 is installed overseas, perform proper grounding in accordance with the regulations of the country of installation. • If the power for the entire unit cannot be supplied, connect an exclusive ground wire for the auto loader.
4)
Power supply • Please entrust all wiring, connections and other electrical work to an authorized electrician. • The PT-R4XXX requires a dedicated power supply that should not serve any other machines or devices. • Always provide circuit breakers for the power supply switchboard. • The permitted fluctuation range in the power supply voltage is ± 10%. If you anticipate a greater range of fluctuation than this, stabilize the power supply with an appropriate voltage regulator. • Be sure to install the ground leakage breaker in the power supply switchboard. • Use the ground leakage breaker for 5 mA leakage (dark current) in accordance with the rated current of the PT-R4XXX. • Check that the ground leakage breaker turns ON before starting operation after weekends or vacations. • However, if the diameter of each wire rod is 4 mm or larger, the power supply cable cannot be connected to the power connecting section of the PT-R4300.
PT-R4300 SERVICE MANUAL
§ -19
A. Outline
A.Outline
1. Introduction 1-1.For maintenance personnel 1) Basic cautions · Before doing any electrical work, be sure to turn OFF the power supply switch and fix the power OFF status by using a padlock, etc., in order to prevent accidents such as electrical shock. · Pay attention to your surroundings when working with this unit. · Do not touch any moving parts during operation. 2) About laser safety · Make sure the interlock safety devices are all in place when the user is operating this unit. · Tell the user not to attempt to modify the laser for any reason. · All responsibility for any changes in safety standards due to changes to the class of laser used are the responsibility of the party who altered the machine. For example, if the user has altered the laser, the user bears responsibility. If the CS department of a branch office altered the laser, the CS department bears responsibility. 3) Cautions about chemicals · Be sure to handle lens cleaners and isopropyl alcohol properly. 4) Cautions concerning static electricity · Use an anti-static wristband and anti-static bags to prevent the buildup of static electricity when handling or transporting parts such as circuit boards or laser diodes, which can easily be damaged by static electricity. 5) About the laser diode · The PT-R4XXX uses a high-output semiconductor laser. If procedures and safety guidelines are not followed correctly, the radiation from the laser diode may injure your eyes. Note that the laser diode can be damaged by static electricity.
The laser diode is extremely sensitive to static electricity. Damage to it from static electricity may result in a shortening of the laser’s service life.
PT-R4300 SERVICE MANUAL
A-1
A.Outline 6) Safety measures to prevent static electricity buildup · Before turning on the power supply, always make sure the power supply is properly grounded. · Wear an anti-static wristband to avoid any buildup of static electricity on your body. · Wear semiconductor laser radiation shaded safety goggles (glasses) to protect your eyes. 7) Safety and static electricity buildup prevention equipment · To maintain safety and prevent the excessive buildup of static electricity, make sure you have the following tools. · Anti-static wristband. Semiconductor laser radiation shaded safety goggles (glasses) Laser type : Laser Diode Wavelength : 790 to 850 NOTE! In the PT-R4300, PT-R4000, and PT-R4000II, there are no operations that require the use of safety goggles.
A-2
PT-R4300 SERVICE MANUAL
A.Outline 1-2.Laser maintenance and safety 1) Under normal conditions When all of the metal plates encasing the PT-R4XXX are in place, the entire machine can be thought of as a single area. Anything within that area is within the laser work area, while anything outside it is outside the laser work area. All of the metal plates are fitted with interlock devices that shut off power to the laser if the plates are removed, preventing the laser from turning on unexpectedly. This means that only the mildest laser safety standards, Class 1, are required. 2) While performing maintenance with metal plates removed After removing the covers and disabling the interlocks, the entire room in which the PT-R4XXX is housed should be considered a laser work area. This means that laser safety standards for CLASS 4 units must be followed. NOTE! In the PT-R4300, PT-R4000, and PT-R4000II, there are no exposure operations that are performed while the metal plates are removed and the interlocks are released. 3) When working with the laser and related parts When focusing or optically adjusting the laser, follow the rules indicated below. · Do not bring any flammable objects into the laser work area. · Do not place any objects with a reflective surface near the path of the laser beam. (e.g. rings, watches, glossy or shiny plated Allen wrenches) · In order to shrink your pupils, make the room as bright as possible. · Use semiconductor laser radiation safety goggles (glasses). · Display a sign limiting entry to the laser area to those working on the laser, in order to prevent accidents to other personnel. NOTE! In the PT-R4300, PT-R4000, and PT-R4000II, no laser operations are performed while the power is being supplied.
PT-R4300 SERVICE MANUAL
A-3
A.Outline 1-3.Basic information 1) Not if or when, but which . . . Dainippon Screen has developed the CTP products and introduced them to the market in 1999. These products have gained wide market acceptance because of their superior quality as well as their user-friendliness, and we have shipped more than 1100 of the PT-R8000 and PT-R4000 units within two years. For the PT-R4000 units, not only is there a thermal CTP market in Japan but the sale ratio of these units has also been significantly expanded over seas. The PT-R4000 unit that is compatible with the SM-74CD sheet-fed press that is used in the package industry in U.S. is needed in order to expand product sales. Therefore, we have improved the specifications of the PT-R4000II and developed the PT-R4300 advanced thermal 4-page plate recorder. 2) The perfect recorder for thermal Though CTP started with light-sensitive plates, thermal plates are clearly the up and coming media of choice. They offer crisper, sharper dots, don’t require darkroom processing, and support longer run lengths. PlateRite 8600 is the perfect recorder to reap all the benefits of thermal imaging. 3) Reap the thermal advantage with PlateRite 4300 While visible-light CTP requires a dark room or special processing, thermal plates are imaged with heat rather than light so they can be handled under yellow or ultraviolet-filtered white light. PlateRite 4300’s advanced optical and clamping system images thermal plates with superior productivity, versatility and ease of use. Its advanced plate securing and auto-balance features allow for extremely fast rotation speeds and high productivity. And PlateRite 4300’s ease of use, automation and user friendly interface make it a snap to use. 4) Try speed We’ve broken the mold. Our external drum spins not just a little faster, but many times faster than conventional external drum plate recorders. PlateRite 4300’s plate securing system allows much faster spin speeds. Automatic variable positioning of trailing edge clamps means that a wide range of plate sizes can be accomodated automatically.
A-4
PT-R4300 SERVICE MANUAL
A.Outline 5) Fast external drum with multi-channel recording Because of the level of heat required to image thermal plates, the light source has to either have a lot of power or be very close to the plate. External drum recorders can position the light source close to the plate, but up to now, drum speeds have been limited by the difficulty of securing the plates well enough to tolerate higher rotation speeds. But now we’ve built on our expertise in external drum recording and precision clamping technologies to bring you a 32-channel external drum recorder with a difference - the drum spins many times faster than conventional external drum plate recorders. That’s how we can offer thermal plate output productivity of 20 plates per hour at 2,400 dpi. An advanced, automated, light-weight clamping and vacuum system is the secret of PlateRite 4300’s superior speed and productivity. This system keeps plates fully secure even at the PlateRite 4300’s rapid rotation speeds. As the drum spins at up to 1000 rpms, the laser images in 32-channels creating the ultimate in thermal productivity. 6) Auto-balance to fit different plate sizes The PlateRite 4300 is designed to fit smoothly into your workflow. Autobalance enables recording of different sized plates with no manual adjustment. All you do is input or select the type of plate you want to use and the PlateRite 8600 automatically makes the necessary adjustments to create perfect drum balance for each plate size you use. It can handle a wide variety of plate sizes, from 370 x 500mm (14.6" x 19.7") all the way up to 940 x 1,160 mm (37" x 45.6"), making it easy to tailor plate output to the job at hand. 7) Automatic internal punch The PlateRite 4300 can even punch your plates for you just before imaging, with your choice of optional internal punch block systems that provide exceptional repeatability. You can mount four punch blocks and select punches based on plate sizes and press type. A variety of suitable punches are available. The PlateRite 4300 can change between two punch configurations automatically as required by the automatic media settings. 8) Inline system to extend automation An inline system can be configured which fully automates the stages involved from plate loading and exposing, through to developing. The SA-L4300 single-cassette auto loader can hold up to 100 plates. It automatically detects interleaves between the plates and discharges them. Also, each plate is secured on its back side when being transferred, therefore, the sensitive emulsion side of the plate is not damaged. PT-R4300 SERVICE MANUAL
A-5
A.Outline The MA-L4300 multi-cassette auto loader contains three cassettes and each cassette can hold up to 100 plates. It achieves a continuous operation of multiple jobs that require the use of different sizes of plate. The AT-T4000 transfer system that bridges the PT-R4300 unit and the processor is also provided as an option of this system lineup.
A-6
PT-R4300 SERVICE MANUAL
A.Outline
2. System overview 2-1.System setup diagram
F-PIF
Trueflow Taiga SPACE HQ-510
The PT-R4300 is connected to the host computer by means of a F-PIF cable. For Macintosh systems, page files (PS data) created by software on the computer are converted to bit map data using a software RIP such as HQ-510, and transmitted on-line to the PT-R 4300.
2-2.Recommended configurations [Trueflow] · Ver. 2.01 [Taiga SPACE] · Ver. 4.3 Rev.k or higher (T-RIP600) [HQ-510] · Ver. 5.5 [AD-810] · Ver. 1.03
For details on the specifications of each RIP, refer to the respective installation guides.
PT-R4300 SERVICE MANUAL
A-7
A.Outline
3. Overall configuration chart and part names 3-1.Front view of the main unit Operation door
Operation panel
Front cover External cover filter
3-2.Back view of the main unit
Forced drum stop switch
Punch debris outlet Rear outlet
Peripheral device connectors
Vacuum hose connector Attachment hook for punch debris receptacle Rear cover Power cable connector
A-8
PT-R4300 SERVICE MANUAL
A.Outline 3-3.Plate conveyor view of the main unit Positioning label
Operation door
Ejection guide Plate conveyor rollor
Ejection table
Power switch Plate table
Positioning label
3-4.Peripheral device connectors F-PIF connector(serial)
F-PIF connector(image) Service connector
Blower control connector AT unit connector Power supply connector for blower
PT-R4300 SERVICE MANUAL
A-9
A.Outline 3-5.Inside of front cover Recording drum
Recording head unit
Front cover attachment hooks
3-6.Inside of rear cover Cleaning roller Punching unit(Standard)
Rear cover attachment hooks
Recording drum Rear cover attachment hooks
A-10
PT-R4300 SERVICE MANUAL
A.Outline
4. Electrical wiring 4-1.Block diagram
C O N -P T R 4
P IO - P T R 4 (2 ) or P IO - P T R 4 PC
R S -2 3 2 C
A C S e rvo D r iv e r
R S -2 3 2 C
RCP2
C al
R S -2 3 2 C
B o a rd Laser H ead U n it P IF 2 RB31
HOST
CPU D RV 4pc P IF 1
SPX 32
R S -2 3 2 C
PT-R4300 SERVICE MANUAL
P anel
A-11
A.Outline 4-2.Function of board 1) RCP2 board The RCP2 board contains the CPU and its peripheral devices. It also controls the secondary-scanning stepping motor. The secondaryscanning stepping motor can operate in two different modes; the synchronous mode (in which the secondary-scanning stepping motor operates synchronously with the primary-scanning servo motor when the image is being exposed) and high speed positioning mode (in which the secondary-scanning stepping motor moves to a position at a high speed independent of the operation of the primary-scanning servo motor). The RCP2 board also contains the devices to implement various adjustments synchronously with the signal from the encoder and generate various timing signals for exposing image on plate. 2) RB31 board Receives the image data via the F-PIF. When the board receives enough data to rotate the drum once, it transmits the data to the high-power laser recording head along with the standard signal for exposure. The board also contains the devices for using the machine setting test patterns and applying automatic burn-out to plate. 3) SPX32 board This board helps compensate for image inclination during spiral exposure. This board allows you to switch PIF signal transmissions between 8 and 16 bit signals. 4) PIO-PTR4(2) board / PIO-PYR4 board Controls the primary-scanning servo motor, each sensor and actuator. The control section for the primary-scanning servo motor operates in one of two modes; the drum rotation mode (at high speed) used while exposing the image and the drum positioning mode (at low speed) used when loading and unloading a plate on the drum. The I/O control section controls each stepping motor (which is used to transfer a plate), the input signals (for switches and sensors) and the output signals (for driving solenoids and punch system). 5) CON-PTR4 boards Relays the signals to and from each sensor and actuator. This board also converts the actuator’s control signal into 24V.
A-12
PT-R4300 SERVICE MANUAL
A.Outline 6) Laser head CPU board Equipped with circuits for controlling the high-power laser diode. This board also controls the zoom and focus of the recording head, and the temperature of the Peltier unit. 7) Laser head driver board Feeds back the light intensity output from the high-power laser to the laser head CPU board.
PT-R4300 SERVICE MANUAL
A-13
A.Outline
5. Specifications 5-1.Basic specifications
A-14
PT-R4300 SERVICE MANUAL
A.Outline
PT-R4300 SERVICE MANUAL
A-15
A.Outline
6. Comparison of PT-R4300, PT-R4000 and PT-R4000II
A-16
PT-R4300 SERVICE MANUAL
A.Outline
PT-R4300 SERVICE MANUAL
A-17
A.Outline
A-18
PT-R4300 SERVICE MANUAL
A.Outline Reference) Parts code of the leading edge clamp PT-R4300 (standard 15 mm type) U1254046-00
U1254058-00
Refer to the next pate. PT-R4300(optional 12 mm type) 100030544V00
NOTE! The leading edge clamps for the PT-R4000/4000II are the same as to those for “U1254046-00” of the PT-R4300 (15 mm type). Reference) Leading edge clamp and clamp pin unit PT-R4000/4000II Pin diameter : 3.5mm 15mm/12mm
15mm 8.925mm
PT-R4300(15mm Type) Pin diameter : 3mm 12mm
Cut 15mm 8.125mm
PTR4300(12mmType) Pin diameter : 3mm 12mm
Cut 12mm 8.125mm
PT-R4300 SERVICE MANUAL
A-19
A.Outline Reference) Plate stopper unit
For 15 mm type (PT-R4300/4000/4000II)
For 12 mmtype (PT-R4300)
A-20
PT-R4300 SERVICE MANUAL
A.Outline 7. Restriction of the plate size for the PT-R4300/4000/4000II - When the ends of a plate reach the grooves for securing the trailing edge clamps on the drum, an imaging failure may occur in the effective image area of the plate at the circled positions in the figure below (each corner of the leading and trailing gripper margins). Therefore, the size of plate to be used is restricted, as below. (Common restriction to any thickness of the plate) Restricted plate sizes: 420 mm to 442 mm 702 mm to 722 mm The plate size is restricted only in the secondary scanning direction and the size in the primary scanning direction is not restricted. - We have confirmed that none of those presses in the following list use plates with the restricted sizes.
PT-R4300 SERVICE MANUAL
A-21
A.Outline List of the presses that are compatible with the PT-R4000 (sheet-fed presses)
A-22
PT-R4300 SERVICE MANUAL
A.Outline
PT-R4300 SERVICE MANUAL
A-23
A.Outline
A-24
PT-R4300 SERVICE MANUAL
A.Outline
PT-R4300 SERVICE MANUAL
A-25
B. Installation
B.Installation
1. Installation 1-1.Information required for adjustments during installation The specification of the standard of the leading grip margin and the trailing grip margin of PTR4000(II) and PT-R4300 is as follows. The leading grip margin : 15mm The trailing grip margin : 12mm However, PT-R4300 can set the leading grip margin to 12mm as a factory option. Before installing the machine, check the items listed below. Manufacturer Plate information Punch system
1
Plate length (L)
Plate thickness
BACHER (single)/BACHER (double)/KOMORI/DS/PROTOCOL/ custom specification
Pitch of pin (P) Edge of plate (E) Leading grip margin (G1) Trailing grip margin (G2) Printing machine Manufacturer and model of printing machine Printable area Manufacturer Plate information Punch system
2
Plate width (W)
Plate width (W)
Plate length (L)
Plate thickness
BACHER (single)/BACHER (double)/KOMORI/DS/PROTOCOL/ custom specification
Pitch of pin (P) Edge of plate (E) Leading grip margin (G1) Trailing grip margin (G2) Printing machine Manufacturer and model of printing machine Printable area L
G2
Image
G1
W
E
E
P
PT-R4300 SERVICE MANUAL
B-1
B.Installation 1-2.Installation schedule Installation:
Approx. 3 hours
Wiring and connection: Machine stand-alone operation checks:
Approx. 1 hour Approx. 1 hour
Exposure adjustment: Approx. 3 hours Check and adjustment of connection with host computer:Approx. 6 hours
B-2
Explanation of operation and safety: Punch attachment (option)
Approx. 2 hours (Approx. 2 hours)
Total:
Approx. 2 days
PT-R4300 SERVICE MANUAL
B.Installation
2. Installation conditions 2-1.Dimensions of delivery path A delivery path of at least the following dimensions is required when delivering the machine to the installation site. Width 1760mm or more 1760mm or more 1405mm or more 1405mm or more
PT-R4000(II) PT-R4300 SA-L/MA-L4000 SA-L/MA-L4300
Depth 1150mm or more 1150mm or more 1185mm or more 1230mm or more
Height 1185mm or more 1185mm or more 1020mm or more 1065mm or more
It is the above-mentioned dimensions at the standard installation. Refer to the following page for the minimum dimensions of the machine.
2-2.Dimensions when delivering the machine The following gives the dimensions of the main unit and the blower unit when delivering the machine to the installation site. Main unit Blower unit Main unit Blower unit
PT-R4000(II) PT-R4300 SA-L4000 MA-L4000
Loading unit Cassete Unit (Weight contains three cassettes.)
SA-L4300 MA-L4300
Loading unit Cassete Unit (Weight contains three cassettes.)
Width(mm) 1750 600 1750 600 1395 1395
Depth(mm) 1140 429 1140 429 1175 1175
Height(mm) 1173 361 1173 361 1010 1010
Weight(kg) Approx. 630 Approx. 30 Approx. 645 Approx. 30 Approx. 340 Approx. 375
1195
1175
695
Approx. 390
1395 1395
1217 1217
1055 1055
Approx. 340 Approx. 375
1195
1175
695
Approx. 390
In order for PT-R4000/PT-R4000II to prevent parts becoming useless, the order method of PT-R was as follows. · In PT-R4000 stand alone, please order PT-R4000 and a coating apron (onerous). However, when connecting PT-R4000 and SA-L/MA-L4000, it is not necessary to order a coating apron part. (s/n:101 onward) Since there are few parts which become unnecessary when connecting PT-R4300 SAL/MA-L4300, there are no above order forms.
PT-R4300 SERVICE MANUAL
B-3
B.Installation The following gives the minimum dimensions of the machine when delivering the machine to the installation site. PT-R4000(II) PT-R4300 SA-L/MA-L4000 SA-L/MA-L4300
Width(mm) 1750 1750 1330(*4) 1130(*4)
Depth(mm) 905(*1) 905(*1) 1160(*4) 1160(*4)
Height(mm) 1000(*2) 1000(*3) 990(*4,5) 990(*4,6)
1) The depth given above is for when the front cover, the rear cover, the apron and the hoist attachments are removed from the machine. The depth when removing only the hoist attachments is as follows, PT-R4000(II) : 1030mm PT-R4300 : 1030mm 2) The height given above is for when the operation panel, the casters and adjustment bolts are removed from the machine. 3) The height given above is for when the operation panel, the operation door, the casters and adjustment bolts are removed from the machine. 4) When removing all covers around of the machine. 5) The height given above is for when the casters and adjustment bolts are removed from the machine. 6) The height given above is for when the paper cover(top), the casters and adjustment bolts are removed from the machine.
· When moving the machine, the main unit must not be tilted. · There is a punch unit in the rear of a machine. Therefore, when you installate a PTR4000/4300, please do not remove a back cover.
B-4
PT-R4300 SERVICE MANUAL
B.Installation 1140 1750
1030
1178
1000
905
(mm)
Dimensional drawing of PT-R4000/PT-R4000II(At the time of installation) 1140 1750
1030
1178
1000
905
(mm)
Dimensional drawing of PT-R4300(At the time of installation)
429
361
600
Dimensional drawing of Blower unit (At the time of installation) (Common to PT-R4000, PT-R4000II, and PT-R4300)
PT-R4300 SERVICE MANUAL
B-5
B.Installation 1395
1217
The paper cover (top)
1160
990
1055
1330
Dimensional drawing of SA-L4300/MA-L4300 Loading unit (At the time of installation)
1175
1195
695
1185
MA-L4300 Cassete unit (At the time of installation)
B-6
PT-R4300 SERVICE MANUAL
B.Installation 2-3.Dimensions when the machine is installed · PT-R4000(II) Width: 1750 mm Depth: 1030 mm Height (* 1): 1178 mm (* 2 Max. 1550 mm)
1) The height given above is from the casters. 2) This dimension is the maximum height when the door is open.
Main unit power cable connection
(mm)
1178
125
235
160
1750
1500
75
125
Main unit power cable insertion port
125
240
400
Blower hose connection
240
Cable connection
1030
97.5
655
107.5
350
1550
Dimensional drawing of PT-R4000/PT-R4000II
PT-R4300 SERVICE MANUAL
B-7
B.Installation · PT-R4300 Width: Depth:
1750 mm 1030 mm
Height (* 1): 1178 mm (* 2 Max. 1537 mm)
1) The height given above is from the casters. 2) This dimension is the maximum height when the door is open.
(mm)
1178 335
Main unit power cable connection
125
250
145
Optional power cable connection Main unit power cable insertion port 200
Optional power cable insertion port
1750
1500
125
75
160
125
240
400
Blower hose connection
240
Cable connection
1030
97.5
655
107.5
350
1537
Dimensional drawing of PT-R4300
B-8
PT-R4300 SERVICE MANUAL
B.Installation · Blower unit (Common to PT-R4000, PT-R4000II, and PT-R4300) Width : 429 mm, Depth : 600 mm, Height : 391 mm 600
429
361
Blower hose connection
Blower control cable connection
40 130 210
Blower unit power cable connection (mm)
Dimensional drawing of Blower unit
· SA-L4300 Width : 1395 mm, Depth : 1775 mm, Height : 1055 mm 1395
1775 1217 389
1055
1175
230
920 550
600
52
1044
130
Dimensional drawing of SA-L4300
PT-R4300 SERVICE MANUAL
B-9
B.Installation
81 1044 640
52
1175
1217
1775
389
· MA-L4300 Width : 2590 mm, Depth : 1775 mm, Height : 1055 mm
135
135 305 575
1055 695
550
1040
600
2590
216
1325
1038
71
1175
Dimensional drawing of MA-L4300
B-10
PT-R4300 SERVICE MANUAL
B.Installation · SA-L4000 Width : 1395 mm, Depth : 1720 mm, Height : 1010 mm
· MA-L4000 Width : 2590 mm, Depth : 1720 mm, Height : 1010 mm
PT-R4300 SERVICE MANUAL
B-11
B.Installation
(when attaching/ detaching)
· AT-T4000 Width : 835 mm, Depth : 1080 mm, Height : 960 mm
B-12
PT-R4300 SERVICE MANUAL
B.Installation 2-4.Installation space and layout position Be sure to secure spaces as follows so that the machine can be operated and maintenance can be performed. 429
200
Blower unit control cable (2m) Blower unit power cable (2m) Blower hose (2m)
800
1750
1000
1000
1030
800
600
200
200
(mm)
PT-R4000/PT-R4000II layout 429
200
Blower unit control cable (2m) Blower unit power cable (2m) Blower hose (2m)
800
1750
1000
1000
1030
800
600
200
200
(mm)
PT-R4300 layout
PT-R4300 SERVICE MANUAL
B-13
B.Installation
835
1080
[Reference]Stocker [Reference]PD-T1094 AT-T4000
10
1120
32
1130
1750
PT-R4000
518
860
6300
10
190
1175
275
SA-L4000
80
610
Min.800
Min.1500
1110
PT-R4000/PT-R4000II, SA-L4000 layout
B-14
PT-R4300 SERVICE MANUAL
B.Installation
835
1080
[Reference]Stocker [Reference]PD-T1094
518
1115
PT-R4000
860
6330
10
190
AT-T4000
965
10
1120
32
1130
2865
MA-L4000
1175
275
640
Min.1000
Min. 1000
1110
PT-R4000/PT-R4000II, MA-L4000 layout
PT-R4300 SERVICE MANUAL
B-15
B-16 275 1750
1110 1080
B.Installation
190
80
Min.1500
PT-R4300, SA-L4300 layout
Min.800
965
PT-R4300 SERVICE MANUAL
610
1175 1217 SA-L4300
518
860
10
985 PT-R4300 6300
10
32
835
1120
AT-T4000
[Reference]PD-T1094
1130 [Reference]Stocker
275
PT-R4300 SERVICE MANUAL
Min.1000
1110 2865
1080
190
B.Installation
1115
PT-R4300, MA-L4300 layout
Min. 1000 965
640
1175 1217 MA-L4300
518
860
10
985 PT-R4300
B-17
6330
10
32
835
1120
AT-T4000
[Reference]PD-T1094
1130 [Reference]Stocker
B.Installation 2-5. Environmental conditions 2-5-1.Temperature and humidity Operating temperature range:
18ºC to 26ºC (with no sudden temperature change within a short period)
Optimum operating temperature range: 21ºC to 25ºC Operating humidity range: 40% to 70% (with no condensation) Storage temperature range: Storage humidity range:
10ºC to 40ºC 25% to 75% (with no condensation)
The following describes the calorific values of the machine. Refer to the following values when arranging air conditioning facilities for the room where the machine is located. Including SAL/MA-L Including blower unit
PT-R4000/PT-R4000II
PT-R4300
-
14.4J(3440kcal/13.6kBTU)
10.9kJ(2600kcal/11.4kBTU)
10.9kJ(2600kcal/11.4kBTU)
SA-L4000/4300 : 3612kJ (860kcal, 3400BTU) MA-L4000/4300 : 2604kJ (620kcal, 2460BTU) AT-T4000 : 251kJ (60kcal, 238BTU)
During the coldest and hottest seasons, the room environment may deviate from the above conditions when air conditioning facilities are not run at night or during medium and long-term intermissions. In such cases, turn ON the air conditioning facilities and power to the machine, and warm up the machine one or two hours prior to operation. The power to the machine must be turned ON, because the air conditioning facilities alone cannot circulate air inside the machine. Follow the procedure below to prevent condensation with sudden temperature change. • Two hours before machine operation, set a timer and start operating the air conditioning facilities. • An hour before machine operation, turn ON the power to the machine. If the air conditioning facilities to be used are equipped with a humidifying function, turn ON the power to the machine first.
B-18
PT-R4300 SERVICE MANUAL
B.Installation 2-5-2.Floor load capacity Weight
The floor minimum load capacity
The weight of the load on one adjustment bolt
PT-R4000(II)/PT-R4300
Approx. 630 kg
3920 N/m2 (400 kgf/m2)
MAX approx. 160 kg
SA-L4000/4300
Approx. 340 kg (*1)
2784 N/m2 (284 kgf/m2)
MAX approx. 85 kg (*1)
Whole unit
Approx. 765 kg (*1,2)
5145 N/m2 (525 kgf/m2)
-
Loading unit
Approx. 375 kg
-
MAX approx. 94 kg
Cassete unit
Approx. 390 kg (*1,2)
-
MAX approx. 98 kg (*1,2)
MA-L4000/4300
1) When not setting plates. 2) When setting three cassets.
2-5-3.Floor levelness Choose an installation site with the most level floor. Six adjustment bolts are attached to the machine for level adjustment; these bolts can be adjusted to within 10 mm. 2-5-4.Vibrations The following are the vibration criterion for machine installation in both the vertical direction and horizontal direction. 0.03 m/s2 (3.0 Gal) or less (Within DC to 60 Hz) 2-5-5.Room cleanliness The installation site must be well ventilated and relatively dust-free.
PT-R4300 SERVICE MANUAL
B-19
B.Installation 2-6.Power requirements The following describes the power requirements for the machine. PT-R4000/PT-R4000II Including blower Single-phase 200 to 230V – 10% 15A unit (50/60Hz) Including SAL/MA-L
PT-R4300 Single-phase 200 to 240V +6%,-10% 15A 3.0kW(50/60Hz) Single-phase 200 to 240V +6%,-10% 20A 4.0kW(50/60Hz)
For safety, power to the SA-L/MA-L should be turned OFF when the power to the main unit is turned OFF. Therefore, PT-R4300 is changed so that the power supply of SAL4300/MA-L4300 can be connected. SA-L4000/MA-L4000 Single-phase 200 V to 230 V ± 10% 5 A 1.0 kW (50 Hz/60 Hz) SA-L4300/MA-L4300 Single-phase 200 V to 240 V +6%,-10% 5 A 1.0 kW (50 Hz/60 Hz) AT-T4000 Single-phase 100 V to 120 V ± 10% 1.1 A (50 Hz/60 Hz) Single-phase 200 V to 230 V ± 10% 0.55 A (50 Hz/60 Hz)
• The machine requires a dedicated power supply. Be sure to ground the AC outlet in the specified manner (grounding resistance: 100 W or less) for machines designed to Japanese specifications. For overseas specifications, follow the manner that specified in standard of each country. • Only connect devices designated for use with the main unit. • If you anticipate a greater range of fluctuation in the power supply voltage than the range described above, stabilize the power supply with an appropriate voltage regulator. • Make sure that the power supply voltage fluctuations are moderate, i.e., there are no spikes or noise.
B-20
PT-R4300 SERVICE MANUAL
B.Installation 2-7.Cable and hose lengths The following describes the lengths of cables and hoses that are to be attached to the main unit and blower unit. Main unit • Power cable: 10 m (CAUTION 1) Blower unit • Power cable: 2 m • Blower hose: 2 m • Blower unit control cable: 2 m
1) About power cable The power cables of the main unit and the blower unit are only provided for machines with Japanese specifications, not with overseas specifications. For machines with overseas specifications, power cables must conform to the given country’s standards, must be able to handle AC 300 V, and must have three cable leads of at least 2.5 mm2. However in case of PT-R4300, as a part of cable comes in power terminal when connecting, you can not connect power cable if the thickness of power cable itself is more than 4mm. 6 to 7mm
4mm or less
2.5mm
2) About lengths of blower hose and gas suction hose Depending in the installation conditions, the blower unit hose can be cut and shortened. However, whenever you cut the hose at the customer site, be sure to refasten the hose end to its cuffs with silicon adhesives to prevent any air leakage.
PT-R4300 SERVICE MANUAL
B-21
B.Installation
3. About transportation 3-1.Transporting the main unit using the forklift (or similar equipment) When lifting the main unit using equipment such as a forklift, be careful about the positions of casters and hoist brackets. Make sure to insert the forks of equipment into the back of the main unit, as shown below.
If the forks are not inserted into the back of the main unit, the frame of the main unit may be damaged.
Forks of equipment
Forks of equipment
3-2.Transporting the main unit by hoisting it When hoisting the main unit, attach the hoist attachments in PT-R4300. The belt should not touch the main unit using the side board currently used for packing of PT-R. The side board currently used for packing of PT-R
B-22
PT-R4300 SERVICE MANUAL
B.Installation
4.Installation procedure 4-1.Packing list check Be sure to check the packing list (included with the equipment packaging) to determine if there are any missing items.
4-2.Assembly 4-2-1.Installation of the PT-R4300 1) Hoist attachment removal There are two hoist attachments on both the front and rear sides of the main unit. First remove the connecting beam and then remove the hoist attachments.
Hoist attachment (front) (Label No. 8)
PT-R4300 SERVICE MANUAL
Hoist attachment (rear) (Label No. 8)
B-23
B.Installation 2) Installation of the main unit Install the main unit using leveling bolts. The unit's casters should be set at 11 mm above the floor surface as shown in the figure. Adjust all leveling bolts uniformly so that they touch the floor surface evenly.
11
95
Be aware that if the distance between the bottom of casters and the floor surface exceeds 22 mm, the leveling bolts may detach from the main unit.
(mm)
4-2-2. Removing the transport fixing brackets The number of the transport fixing brackets for each PT-R unit is as follows. Note that the number for the PT-R4300 varies with the serial number. PT-R4000, PT-R4000II: 17 transport fixing brackets (including the hoist attachments mentioned earlier) PT-R4300 (s/n: 1 to 6, 8): 17 transport fixing brackets (including the hoist attachments mentioned earlier) PT-R4300 (s/n: 7, 9 onward): 19 transport fixing brackets (including the hoist attachments mentioned earlier) In addition, five cushioning materials are used. These transport fixing brackets are common to the PT-R4000, PT-R4000II, and PT-R4300. Ensure that all of them have been removed finally. The tag shown below is attached to each transport fixing bracket. Note, however, that it is not attached to the cushioning materials.
B-24
PT-R4300 SERVICE MANUAL
B.Installation 1) Open the operation door. The method to open the operation door while the power to the main unit is OFF varies with the PT-R4000 (II) and the PT-R4300. • PT-R4000/PT-R4000II Removing the fixing brackets from the clamp roller Insert a thin rod (e.g., a hexagonal wrench) into the door-releasing hole for the operation door, which is located at the bottom surface of the plate table, to open the operation door.
• PT-R4300 Insert a thin rod (e.g., a hexagonal wrench) into the door-releasing hole for the operation door, which is located at the right section of the plate table, and lower the rod. This will open the operation door.
2) Remove all covers from the main unit.
PT-R4300 SERVICE MANUAL
B-25
B.Installation 3) Remove the fixing brackets, shown below, from the front of the main unit. Fixing bracket for the recording head board unit. (Label No.3)
Away side on the front side (Label No.5)
B-26
Home side on the front side (Label No.7)
PT-R4300 SERVICE MANUAL
B.Installation For the PT-R4300 (s/n: 7, 9 onward), remove the fixing brackets shown in the following figures in addition to those in the above figures.
PT-R4300 SERVICE MANUAL
B-27
B.Installation 4) Remove the fixing brackets, shown below, from the back of the main unit. Transfer unit fixing bracket (Home) (Label No. 9)
Transfer unit fixing bracket (Away) (Label No. 12)
Cleaning roller fixing bracket (Home) (Label No. 10)
Squeeze roller side plate fixing bracket (Home) (Label No. 16)
Clamp section fixing bracket (Home) (Label No. 13)
B-28
Cleaning roller fixing bracket (Away) (Label No. 11)
Squeeze roller side plate fixing bracket (Away) (Label No. 17)
Clamp section fixing bracket (Away) (Label No. 14)
Blower fixing bracket (rear side) (Label No. 4)
Base fixing bracket (rear side) (Label No. 15)
PT-R4300 SERVICE MANUAL
B.Installation 5) Remove the fixing brackets, shown below, from the right side of the main unit. Recording head unit fixing bracket (Home)(Label No.6)
6) Remove the fixing brackets, shown below, from the left side of the main unit.
Recording head unit fixing bracket (Away)(Label No.2)
Blower fixing bracket (Label No.4)
PT-R4300 SERVICE MANUAL
Fixing bracket for the ball screw. (Label No.1)
B-29
B.Installation 7) Remove the cushioning materials, shown below, from the front and rear sides of the main unit. Discharge tray
Remove
Remove these cushioning materials to remove the discharge tray.
Remove
Protection material for the discharge roller
B-30
PT-R4300 SERVICE MANUAL
B.Installation • Fixing bracket list The PT-R4300 uses the fixing brackets listed below. Be careful not to lose any of them, including their attachment screws. For the PT-R4300 (s/n: 7, 9 onward), two more fixing brackets are used in addition to the following ones. (Refer to page B-27.) Frame fixing bracket (1 type, 3 pcs.)
Transfer unit fixing bracket (3 types, 4 pcs.)
Clamp drive section fixing bracket (6 types, 6 pcs.)
Recording head unit fixing bracket (3 types, 3 pcs.)
Ball screw fixing bracket (1 type, 1 pc.)
Squeeze roller and cleaning roller fixing brackets (4 types, 4 pcs.)
When the PT-R4300 needs to be moved after installation, shift the recording head to the 365 mm point where the fixing brackets can be roughly adjusted. Use a lateral feed motor knob for the recording head position fine adjustment.
Recording head blower fixing bracket (3 types, 3 pcs.)
Hoist attachment (2 types, 4 pcs.)
PT-R4300 SERVICE MANUAL
B-31
B.Installation 8) Remove the exterior apron jig and attach the apron and door lock system. Next, close the door to ensure that the door lock system functions properly. If the door does not lock properly, adjust the door lock bracket. (This operation is required for the PT-R4000/PT-R4000II with serial numbers 0101 and onward.)
The exterior apron jig
Door lock system
Apron
PT-R4000/PT-R4000II
4-2-3.Adjusting the levelness Although the PT-R4300 does not require leveling, adjust all leveling bolts uniformly so that they evenly touch the floor surface.
B-32
PT-R4300 SERVICE MANUAL
B.Installation 4-3.Connection 4-3-1.Connecting the blower hose and gas suction hose. Connect the blower hose, blower communication cable, and power supply cable between the blower unit and the PT-R main unit. Then, secure the blower power supply cable with a tie band.
• When connecting a blower unit to the main unit using hoses, be sure to confirm that a cuff (joint portion) is firmly attached to each hose end. If a cuff is not adequately fastened to the hose, air leakages are likely to occur. • Always install the blower unit in the room where the PT-R4300 is installed.
Tie band
Blower power supply cable connection
Blower control cable connection
Blower
Blower control cable connection Blower hose connection
Blower power supply cable connection
Tie band Main unit
PT-R4300 SERVICE MANUAL
B-33
B.Installation 4-3-2.Connecting the blower unit control cable
• The connection terminal of the PT-R4000/4000II differs from that of the PT-R4300. Therefore, their power supply cable connection methods are different. • The ground connecting position of the PT-R4000/4000II differs from that of the PTR4300. 1) PT-R4300
Main unit power supply Ground line cable connection connection
Optional power supply cable connection
Power supply cable connections
Main unit power supply cable insertion port
Optional power supply cable insertion port
Power supply cable insertion ports
• Cable stripping 6 to 7 mm
4 mm or less
B-34
2.5 mm
PT-R4300 SERVICE MANUAL
B.Installation • Wiring connection. Please follow as below.
1: Insert screw driver obliquely for operation slot.
2: Insert till the end with screw driver straightly.
3: If it is correct operation, a entrance of that can be opened.
4: Insert the wire in round hole like drawing. At that time if wire is inserted along round hole, that will be smooth.
5: If the wire is inserted till the end, please pull screw driver out with pushing the wire.
6: For confirming, pull the wire slightly.
PT-R4300 SERVICE MANUAL
B-35
B.Installation 2)
PT-R4000/PT-R4000II
Main unit power supply cable connection
Ground line connection
Power supply cable connections
B-36
Main unit power supply cable insertion port Power supply cable insertion port
PT-R4300 SERVICE MANUAL
B.Installation 4-3-3.Connecting an auto loader to the PT-R4300 (option)
For the PT-R4000/4000II, the exterior apron unit needed to be ordered separately in order to prevent any components from being wasted. This order system is not required for the PT-R4300, as there are fewer components to be wasted when connecting the SA-L4300 to the PT-R4300. 1) Remove front cover of PT-R4300.
2) Open operation door of PT-R4300. A hole to open the door manually is right side of operation door.
3) Remove front cover at apron unit of PT-R4300. (4 screws)
Front cover of apron unit.
PT-R4300 SERVICE MANUAL
B-37
B.Installation 4) Remove apron unit of PT-R4300. (6 screws)
2 screws,right side and left side
2 screws at center of apron unit
5) Remove plate insert guide 3 of PT-R4300.(4 screws)
Condition after removing front cover of apron, apron unit and plate insert guide3.
6) Install positioning plate in PT-R4300. (2 pieces)
B-38
PT-R4300 SERVICE MANUAL
B.Installation 7) Connect SA-L/MA-L4300 to PT-R4300. Easy to connect if apron side covers at left and right is loosened not take out completely otherwise hard to fix again. (2 screws inside machine fix them.)
Apron side covers
8) As the rest of procedure to connect is the same as that of PT-R4300 and SA-L/MA-L4300. So please refer to their service manual.
• Nothing changes for shipping brackets though their shape is a little different. • The shape of bridge and external cover is different but nothing changes regarding shipping bracket.
9) The power source of SA-L/MA-L4300 is to be shared from PT-R4300. The way to connect power source at PT-R4300 is changed. Please connect Grand (earth) onto power terminal not machine frame. Power terminal is also changed. It is quite new type so that please refer to attached procedure. For information on cable connections and how to connect the power supply cables, refer to “4-3-2 Connecting the blower unit control cable” on page 34. 10) When you connect SA-L/MA-L to PT-R, set height of guide at PT-R and that at Bridge unit to be parallel . If they are not paralell each other, thin and small plate will not be transported well.
PT-R4300 SERVICE MANUAL
B-39
B.Installation 4-4. Start of the machine
Before turning ON the power to the main unit, check one more time whether all transport fixing brackets removed. 1) Turn ON the power to the main unit to start up the main unit.
PT-R4300
PT-R4000/4000II
B-40
PT-R4300 SERVICE MANUAL
B.Installation 2) The screen on the left appears on the panel of the main unit, and the PT-R4300 memory check starts. Memory check progress!! Please wait.
If an error occurs during the memory check, the screen on the left will be displayed. Memory check error Please download control program.
If this screen is displayed, be sure to download the system software from the host computer.
3) When the memory check is completed, the screen on
0101
the left appears. Press [START] to start the initialization of the PT-
P T- R 4 3 0 0
R4300.
Please press [START]
START
’02.05.01 V1.00
The screen on the left is displayed during the initial-
0200
ization. Initializing ! ! Please wait.
The Online (Ready) Screen appears after the machine initialization is completed.
0200
Ready 1 : 1: Plate 1
OFFLINE
PT-R4300 SERVICE MANUAL
OPEN
B-41
B.Installation 4-5.Initial settings 4-5-1.Outline for panel settings The information settings in the PT-R4300 have the following configuration. This information must be set before a plate can be loaded in the PT-R4300 and exposed. Printing machine information
Plate information
Comments
Comments
Plate information number Grip direction Front and trailing grip margins Centering Offset when centering is OFF
Media type information number Size
Punch number Positioning punch ON/OFF Fine adjustment of image position
Comments (Punch block number) (Punch interval)
Punch information
Media type information Comments Thickness Positive type/negative type Balancer constant setting Light intensity for each resolution Rotational speed for each resolution Focus for each resolution Zoom for each resolution Primary scanning length correction for each resolution
Exposure conditions Mirror Negative/positive Layout Offset for multi-output
(1) Media type information (Same meaning as “plate type information”.) This sets information regarding the plate manufacturer, model number, and thickness. Fifteen type can be registered. In addition to the fifteen types (Nos. 1 through 15) that can be registered, there are also fifteen types (Nos. 31 through 45) that have been preset, and these can be copied to Nos. 1 through 15. (2) Plate information This sets the plate size and media type information number. Fifteen types can be registered. (3) Printing machine information This sets the plate information number, grip, centering, and punch information. Fifteen types can be registered. (4) Punch information This stores punch comments. Nine types can be registered. (Note that there is limit to the number of punch units that can be attached.) A service technician sets the punch block number and punch interval when he installs an optional punch mechanism. (5) Exposure conditions Only one type can be registered. These settings are effective regardless of the printing machine information selected.
• Set the information in the following order: media type information, plate information, printing machine information, and then exposure conditions. • When you instruct the host computer to output to the PT-R4300, the plate data set in the printing machine information that was selected when the plate was loaded is automatically selected, and output takes place according to the conditions set in the printing machine information.
B-42
PT-R4300 SERVICE MANUAL
B.Installation 4-5-2.Setting the media type As many as 15 types of detailed information concerning the output media can be registered. The procedure for setting the information is as follows: Select a media type number. ↓ (Copy preset media type information.) ↓ Enter comments and select negative or positive. ↓ Set the plate thickness and the balancer constant. ↓ Select the light intensity and the drum rpm. ↓ Set the focus value. ↓ Set the zoom value and the absolute precision correction value. 0300
1) In the offline screen, select [Set media type] and
Set printing machine
press [OK]. The media type setting screen will appear.
Set plate Set media type Set exposure mode User maintenance ONLINE
OK
NEXT
2) Select a number to set the media type and press
1150
1
Media Type 1
2
Media Type 2
3
Media Type 3
4
Media Type 4
5
Media Type 5
ESC
OK
[OK]. The screen shown in step 3) will appear. Pressing [NEXT] in the screen on the left moves you to the next media type setting screen. Pressing [ESC] returns you to the offline screen.
NEXT
3) Press [Copy form]. The screen shown in step 4) will appear.
1100
Comment Media Type 1
Posi
ESC
Nega
OK
PT-R4300 SERVICE MANUAL
Copy form
B-43
B.Installation 4) Select the preset media type to be copied. Press
1057
31
FUJIFILM LH-PI 0.24mm
32
FUJIFILM LH-PI 0.30mm
33
FUJIFILM LH-NI 0.24mm
34
FUJIFILM LH-NI 0.30mm
35
KODAK IR 0.24mm
ESC
OK
[NEXT] several times to display the screen that includes preset media types from No. 31 onward. If the information (manufacturer, model number, and thickness) in one of the preset media types is the
NEXT
same as the media you intend to use, press that number and then [OK]. The selected media type information will be copied to the media type number that you selected above, and then the screen shown in step 5) will appear.
36
KODAK IR 0.30mm
If the media type that you intend to use is not in the screen on the left, press [ESC]. The screen shown in
37
Media Type 37
step 5) will appear.
38
Media Type 38
39
Media Type 39
40
Media Type 40
1058
ESC
OK
NEXT
5) Press [Comment]. The screen shown in step 6) will
1100
appear.
Comment Media Type 1
Posi
Nega
ESC
OK
Copy form
ESC
6) Enter a comment of media type in the screen on the left.
@
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
]
^
CLR
SPC
Flips through the entry screens for upper case letters, lower case letters, and symbols/numbers. BS
BS
ENT CLR SPC
Moves the cursor. Deletes the letter to the left of the cursor. Clears the entered comment. Enters a space.
Returns to the screen shown in step 5). After entering a comment, press [ESC]. The screen ESC
shown in step 7) will appear.
B-44
PT-R4300 SERVICE MANUAL
B.Installation 7) Select [Posi] (positive) or [Nega] (negative) for the
1100
media type, and press [OK]. The screen shown in step 8) will appear.
Comment Media Type 1
Posi
Nega
When positive plate is exposed, the section exterior to the image will be burned out. ESC
OK
Copy form
1101
CLR 0.24 mm
Thickness Front offset
0.00 Displancement offset -9.99 mm ESC
7
8
9
4
5
6
1
2
3
0
•
Thickness: Plate thickness (mm) Allowable range: 0.00 to 9.99 Front offset: Offset value for the leading edge sensor Allowable range: -50.0 to 50.0 Refer to page B-62 for the adjustment method. Displacement: Offset value for the displacement
ENT
OK
8) Specify the following values in the screen on the left.
sensor Allowable range: -9.99 to 1.000 Refer to page B-63 for the adjustment method. Press [OK] at the end, and the screen shown in step 9) is displayed. When you have copied data in step 4), confirm that the value displayed in this screen is correct.
1101
CLR
Distance limit 20
ESC
7
8
9
4
5
6
1
2
3
0
•
Distance limit: Threshold value of the displacement sensor Allowable range: 20 to 100 Do not change the input value as it is fixed.
ENT
OK
9) Specify the following value in the screen on the left.
Press [OK] at the end, and the screen shown in step 10) is displayed.
1102
dpi
CLR
1200
[%] 80.0
[rpm] 1000
2000
81.0
1000
2400
82.0
1000
4000
83.0
1000
2438
84.0
1000
2540
85.0
1000
ESC
OK
7
8
9
4
5
6
1
2
3
0
• ENT
10) Enter values into the following fields in the screen on the left. : Light intensity (%) Allowable range: 10.0 to 100.0 : Drum rpm (rpm) Allowable range: 300 to 1000 Press [OK]. The screen shown in step 11) will appear. If you copied the preset data in step 4), check that the displayed information is correct.
PT-R4300 SERVICE MANUAL
B-45
B.Installation 1103
dpi
CLR [pulse]
1200
1930
2000
2000
2400
1930
4000
2000
2438
1910
2540
1860
ESC
7
8
9
4
5
6
1
2
3
0
•
dpi
CLR
1200
[%] [pulse] 0.000 6700
2000
1400
0.000
2400
6700
0.000
4000
1400
0.000
2438
7250
0.000
2540
8550
0.000
ESC
7
8
9
4
5
6
1
2
3
0
• ENT
SAVE
Allowable range: 101 to 4000 Press [OK]. The screen shown in step 12) will ap-
displayed information is correct.
1104
R
shown on the left. : Focus value (pulse)
pear. If you copied the preset data in step 4), check that the
ENT
OK
11) Enter values into the following fields in the screen
12) Enter values into the following fields in the screen shown on the left. : Zoom value (pulse) Allowable range: 201 to 17000 R
: Correction value for primary scanning direction length (%)
Allowable range: -1.000 to 1.000 Example) If this value is initially 0 and an image is exposed that is 800 mm in the primary scanning direction, but the exposed image is actually 799 mm, entering a correction value of (800 - 799)/800 x 100 = 0.125 (%) will cause the correct length to be exposed. Press [SAVE]. The screen shown in step 13) will appear. If you copied the preset data in step 4), check that the displayed information is correct. 13) Press [YES] and then [OK] to save the data. If you want to cancel the save, press [NO] and then
1158
Save Data ? YES
ESC
B-46
NO
[OK]. Pressing [ESC] returns you to the screen shown in step 12).
OK
PT-R4300 SERVICE MANUAL
B.Installation 4-5-3.Setting the plate As many as 15 types of output plate information can be individually registered. The procedure for setting the information is as follows: Select a plate number. ↓ Enter comments and select the media type. ↓ Set the plate size. 0300
1) Select [Set plate] and press [OK]. The plate setting
Set printing machine
screen will appear. Set plate Set media type Set exposure mode User maintenance ONLINE
OK
NEXT
2) Select a number to set the plate setting and press
1050
1
Plate 1
2
Plate 2
3
Plate 3
4
Plate 4
5
Plate 5
ESC
[OK]. The screen shown in step 3) will appear.
OK
NEXT
3) Press [Comment] in the screen on the left. The screen shown in step 4) will appear.
1000
Comment
When you intend to copy the data from the preset plate settings, press [Copy form]. In the screen that
Plate 1 Media
appears, select the desired plate setting number and press [OK]. The screen shown in step 3) will appear.
Media Type 1
ESC
OK
PT-R4300 SERVICE MANUAL
Copy form
Then press [Comment]. The screen shown in step 4) will appear.
B-47
B.Installation ESC
4) Enter a plate setting comment in the screen on the left.
@
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
]
^
CLR
SPC
Flips through the entry screens for upper case letters, lower case letters, and symbols/numbers. BS
BS
ENT CLR SPC
Moves the cursor. Deletes the letter to the left of the cursor. Clears the entered comment. Enters a space.
Returns to the screen shown in step 3). After entering a comment, press [ESC]. The screen ESC
shown in step 5) will appear.
The comment entered here will appear in the screen that asks you to set a plate and the screen that asks you to select a plate to be set. We recommend that you enter the size name, size, and thickness (and the media type name when using multiple media types) as shown in the following example. Kiku-Han 650 x 550 0.3 mm LH-PI 5) Press [Media] in the screen on the left. The screen
1000
shown in step 6) will appear.
Comment Plate 1 Media Media Type 1
ESC
OK
Copy form
6) Select the desired data number from the preset media types and press [OK]. The screen shown in step 7)
1150
1
Media Type 1
2
Media Type 2
3
Media Type 3
4
Media Type 4
5
Media Type 5
ESC
B-48
OK
will appear. If you copied the preset data in step 3), check that the displayed information is correct. The media type information that you selected in the NEXT
screen on the left will be linked to the plate that is being set.
PT-R4300 SERVICE MANUAL
B.Installation 7) Press [OK] in the screen on the left. The screen
1000
shown in step 8) will appear.
Comment Plate 1 Media Media Type 1
ESC
OK
Copy form
1001
CLR
Size [mm] 830.0
645.5
ESC
7
8
9
4
5
6
1
2
3
0
• ENT
SAVE
Plate width (mm) Allowable range: 323.0 to 831.0 Plate length (mm) Allowable range: 369.0 to 661.0 If you copied the preset data in step 3), check that the displayed information is correct. Press [SAVE]. The screen shown in step 9) will appear. 9) Press [YES] and then [OK] to save the data.
1158
Save Data ? YES
ESC
8) Enter values into the following fields.
NO
If you want to cancel the save, press [NO] and then [OK]. Pressing [ESC] returns you to the screen shown in step 8).
OK
PT-R4300 SERVICE MANUAL
B-49
B.Installation 4-5-4.Setting the printing machine information When outputting a plate with the PT-R4300, output conditions such as the media type, leading grip margin, trailing grip margin, and image centering can be linked and saved as printing machine information. As many as 15 types of printing machine information can be individually registered. The procedure for setting the information is as follows: Select a printing machine number. ↓ Enter comments and select the plate. ↓ Set the grip direction. ↓ Set the leading and trailing grip margins. ↓ Set the image centering method. ↓ Set the image position offset. ↓ Set the punch. ↓ Fine adjust the image position. 0300
1) Select [Set printing machine] and press [OK]. The
Set printing machine
printing machine setting screen will appear. Set plate Set media type Set exposure mode User maintenance ONLINE
OK
NEXT
2) Select a number to set the printing machine setting
0000
1
Printing machine 1
2
Printing machine 2
3
Printing machine 3
4
Printing machine 4
5
Printing machine 5
ESC
B-50
OK
and press [OK]. The screen shown in step 3) will appear.
NEXT
PT-R4300 SERVICE MANUAL
B.Installation 3) Press [Comment] in the screen on the left. The
0900
screen shown in step 4) will appear. When you intend to copy the data from the preset
Comment Plate 1
printing machine settings, press [Copy form]. In the screen that appears, select the desired printing ma-
Plate Media Type 1
ESC
OK
Copy form
ESC @
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
]
^
CLR
SPC
chine setting number and press [OK]. The screen shown in step 3) will appear. Then press [Comment]. The screen shown in step 4) will appear. 4) Enter a printing machine setting comment in the screen on the left. Flips through the entry screens for upper case letters, lower case letters, and symbols/numbers. Moves the cursor. BS
BS
ENT
CLR SPC ESC
Deletes the letter to the left of the cursor. Clears the entered comment. Enters a space. Returns to the screen shown in step 3).
After entering a comment, press [ESC]. The screen shown in step 5) will appear. 5) Press [Plate] in the screen on the left. The screen shown in step 6) will appear.
0900
Comment Plate 1 Plate Media Type 1
ESC
OK
Copy form
6) Select the desired data number from the plate set-
1054
1
Plate 1
2
Plate 2
3
Plate 3
4
Plate 4
5
Plate 5
ESC
tings and press [OK]. The screen shown in step 7) will appear. If you copied the preset data in step 3), check that the displayed information is correct. The plate setting that you selected in the screen on the left will be linked to the printing machine that is OK
PT-R4300 SERVICE MANUAL
NEXT
being set.
B-51
B.Installation 7) Select the grip direction and press [OK]. The screen
0901
Spiral/Step
shown in step 8) will appear. : Allows you to set horizontal gripping (at the top and bottom) of the plate. : Allows you to set vertical gripping (at each
Grid direction
side) of the plate. ESC
OK
0902
Grip [mm]/ After Grip
CLR 7
8
9
4
5
6
1
2
3
0
•
8) Enter values into the following fields. : Leading grip margin/Grip (mm) Allowable rage: 0.0 to 999.9
0.0 mm
: Trailing grip margin/After Grip (mm) 0.0 mm
ESC
OK
Allowable rage: 0.0 to 999.9 Press [OK]. The screen shown in step 9) will appear.
ENT
9) Select the desired centering method and press [OK]. The screen shown in step 10) will appear.
0903
Centering in primary scanning direction: OFF Centering in secondary scan-
Centering
ning direction: ON ESC
OK
Centering in primary scanning direction: ON Centering in secondary scanning direction: ON Centering in primary scanning direction: OFF Centering in secondary scanning direction: OFF Centering in primary scanning direction: ON Centering in secondary scanning direction: OFF If multi-output is set in the exposure condition settings, the settings for image centering in the secondary scanning direction and the image offset in the secondary scanning direction described below will be ignored.
B-52
PT-R4300 SERVICE MANUAL
B.Installation 0904
CLR
Offset H
R
0.0 mm
10) Enter values into the following fields. R
8
9
4
5
6
1
2
3
0
•
primary scanning direction (mm)
ENT
Allowable range: 0.0 to 645.0
secondary scanning direction (mm)
Offset V 0.0 mm
R ESC
OK
: Offset for edges of plate and exposure area in
7
Allowable range: 0.0 to 830.0 R
: Offset for edges of plate and exposure area in
The above values are only effective for the direction in which centering is set to OFF. When centering is set to ON both in the primary scanning direction and the secondary scanning direction, the screen on the left will not appear. If multi-output is set in the exposure condition settings, the settings for image centering in the secondary scanning direction and image offset in the secondary scanning direction will be ignored. Press [OK]. The screen shown in step 11) will appear. 11) Press [Punch] in the screen on the left. The screen shown in step 12) will appear.
0905
Punch Off
ESC
OK
12) Select the desired punch type number from the registered punch types and press [OK]. The screen shown
0000
OFF 1
Punch 1
2
Punch 2
3
Punch 3
4
Punch 4
ESC
in step 13) will appear. The punch type that you selected in the screen on the left will be linked to the printing machine that is being set. OK
PT-R4300 SERVICE MANUAL
NEXT
When you do not want to use punching function, press [OFF].
B-53
B.Installation 0906
CLR
Paper Position H
R
0.0 mm
7
8
9
4
5
6
1
2
3
0
•
13) Enter values into the following fields in the screen on the left. R : Correction value for the image output position on the plate (secondary scanning direction) (mm)
Paper Position V
R ESC
0.0 mm
ENT
SAVE
R
Allowable range: -425.5 to 425.5 : Correction value for the image output position on the plate (primary scanning direction) (mm)
Allowable range: -340.5 to 340.5 Press [SAVE]. The screen shown in step 15) will appear. 14) Press [YES] and then [OK] to save the data. If you want to cancel the save, press [NO] and then
1061
Save Data ? YES
ESC
B-54
NO
[OK]. Pressing [ESC] returns you to the screen shown in step 14).
OK
PT-R4300 SERVICE MANUAL
B.Installation 4-5-5.Setting the exposure conditions Set the exposure conditions for mirror image output, positive/negative output, and layout method when outputting on the PT-R4300. 0300
1) Select [Set exposure mode] and press [OK]. The exposure condition setting screen will appear.
Set printing machine Set plate Set media type Set exposure mode User maintenance
ONLINE
OK
NEXT
2) When the SA-L/MA-L is connected, the screen on the left will appear. Select the plate loading method. : Automatic plate loading (transferred from SA-L/MA-L) : Manual plate loading
3) When units including the auto processor are connected, the screen on the left will appear. : Unloads the plate to the rear side (for example the auto processor side) of the main unit. : Unloads the plate to the front side of the main unit.
PT-R4300 SERVICE MANUAL
B-55
B.Installation 4) Select the desired commands from the following and
0702
Mirror
press [SAVE]. Mirror
Posi/Nega
Layout
: Normal image output (Select this for usual operation.) 1
ESC
123
: Mirror image output Posi/Nega : Positive output (Select this for usual opera-
SAVE
tion.) : Negative output Layout : Single output (Outputs one image onto one 1
plate.) (Select this for usual operation.) 123
: Multi-output (Outputs plural images onto one plate.)
1.Caution for Posi/Nega settings Normally “Posi” is selected and the host computer outputs a positive image. The PT-R4300 checks whether the media type is set to positive or negative and then adjusts exposure so that a positive image is output. If the image output from the host computer is a negative image, select “Nega” in the exposure condition setting screen. 2.Caution for (multi-output) of Layout After exposing one image, when the image size that is to be exposed next is smaller than the 123
unexposed area, the plate will be exposed without being unloaded. When the image size that is to be exposed next is larger than the unexposed area, the plate will be unloaded and exposure starts after loading the next plate. If centering in the secondary scanning direction is set to ON in the printing machine settings, exposure of the initial image will begin at a position 5 mm from the edge of the plate (or the leading grip margin). A 5 mm gap is automatically inserted between each image. When performing multi-output using a positive-type plate, the 5 mm gap before the first image, the 5 mm gap between images, and the gap from the edge of the last image to the edge of the plate will be burned out. The burn-out after the last image is executed before unloading. 5) Press [YES] and then [OK] to save the data. If you want to cancel the save, press [NO] and then
0704
Save Data ? YES
ESC
B-56
NO
[OK]. Pressing [ESC] returns you to the screen shown in step 2).
OK
PT-R4300 SERVICE MANUAL
B.Installation 4-6 Operation check and adjustment 4-6-1 Checking the registration Once initialization of the machine has completed correctly, check the registration accuracy according to the following procedure. If you notice any deviations, adjust them according to Chapter C “Replacement & Adjustment”. Registration accuracy should be checked at the same time as the operations described in “4.6.2 Confirming plate winding and exposure”. 1) Ensure that when the transfer path is located at the lowest position, it makes contact with the stopper, which is located on the PT-R4300 side.
Transfer path
Stopper
Enter the Service/Maintenance Menu screen. →Enter the Actuator test screen.
Recording drum
→Lower the transfer path. (By pressing the Down button twice) Ensure that the lower section of the transfer path contacts the stopper.
Ensure that the recording head is positioned on the Home side. Reference) The transfer path must be positioned at 0.5 mm or less from the stopper. (In effect, these two should contact each other, however a 0.5 mm clearance between them can be tolerated.) 2) Next, check the position the plate attaches to the drum using a plate of the maximum size used by the
Nip roller Transfer path
Shutter Leading edge clamp
Plate
user. Enter the Service/Maintenance Menu screen. →Enter the Actuator test screen. →Lower the nip roller. →Open the shutter. →Feed a plate to check the position it attaches to the recording drum. Reference) According to factory adjustment, maximum sized plates (830 x 645, thickness: 0.3) attach to a position nearly under the leading edge clamps. Be aware of plate slack. The thinner the plate is, the more it slacks.
PT-R4300 SERVICE MANUAL
B-57
B.Installation 0 .5 to 1 .0 m m
P la te
3) Ensure that the plate makes contact with the drum from the registration pin side and that it is inclined with respect to the lateral groove on the recording drum. Place a plate on the transfer path.
L a te ra l g ro o ve o n th e re c o rd in g d ru m
→Lower the transfer path to its lowest position. →Lower the nip roller. R e g is tra tio n p in s
F ra m e o f th e P T -R 4 3 00
E n g in e b a s e
→Open the shutter. →Rotate the recording drum by hand and execute Servo ON when the lateral groove comes close to the squeeze roller. →Feed the plate to check the inclination of the plate with respect to the lateral groove on the recording
T h e d is ta n c e b e tw e e n th e H o m e s id e d ista n c e a n d A w a y s id e d ista n c e s h o u ld b e 1 to 1 .5 m m .
162m m
163m m
drum. Reference) When the plate is correctly placed, with respect to the Home side, its Away side tilts from 0.5 to 1.0 mm near the registration pins.
R e c o m m e n d e d e n g in e b a s e tilt
Also check that the engine base tilts with respect to the frame. According to factory adjustment, the engine tilts 1 mm with respect to the frame. (The recording head is positioned on the Home side.) 4) Check that the plate has been correctly positioned in the lateral direction with respect to the registration pins on the recording drum. Plate Registration pin Ensure that both plate punch centers align with the centers of the registration pins. permissible for these punch hole centers to be slightly shifted (within 0.5 mm) to the right
It is .
Ensure that the centers of both punch holes on the plate align with the centers of the registration pins. It is permissible for these punch hole centers to be slightly shifted (within 0.5 mm) to the right. Remove the punch debris guide from the Home side (so that the registration pin area is clearly visible.) →Place a plate on the transfer path. →Set the transfer path to the middle position. →Center the plate and then make punch holes. (Note 1)
If the plate punch centers are significantly shifted to the left or right, plate misregistration will result.
B-58
→Rotate the recording drum to the plate winding position and open the leading edge clamps. →Move the transfer path to the lowest position and open the shutter. PT-R4300 SERVICE MANUAL
B.Installation →Feed a plate and check the positions of the regisApproximately 3 mm from the pin
tration pins and the holes punched in the plate.
Plate
Note 1) A personal computer is required to carry out this operation.
Registration pin
Ensure that the bearings of the centering unit
Ensure that the nip roller is released when the plate reaches a point approximately 3 mm from the registration pins.
contact the respective edges of the plate during punching. 5) Check the timing when the nip roller is released. Remove the plate and initialize the machine. →Load a plate onto the drum. →Ensure that the plate stops for an instant when the leading edge clamps open and the plate is fed to a point approximately 3 mm from the registration pins. Plate
6) Once the head adjustment has been completed, execute test exposure of the grid pattern over the full surface of a plate of the size used by the user. At least four plates are required for the test exposure. On the reference plate (first plate), overlay another plate and cut out its leading edge corners on the Home and Away sides. Then, measure the difference between the grid lines in the Y direction on the plate and the grid lines on the reference plate.
Cut out Bacher register pins (6.35 dia)
• 6.35 dia. register pins (2 pcs.) (Reference) Name: Register pin Parts code: 030100072 • Loupe • 2400 dpi • Grid pattern exposure
PT-R4300 SERVICE MANUAL
B-59
B.Installation Criterion for judgment) At 2400 dpi, the line width is approximately 30 µm. Registration in the PT-R4300 is considered to be accurate when the corresponding grid lines are aligned to within one grid line width at the points specified in the figure.
Approximately 30 mm
Check for misalignment of grid lines in these areas.
Y direction
7) Restore all parts removed, such as the cleaning roller and punch debris guide.
B-60
PT-R4300 SERVICE MANUAL
B.Installation 4-6-2.Confirming plate winding and exposure Confirmation of plate winding load a plate and check the winding. Make sure that none of the plates the customer will use are wrapped, bent or dented. 1) Check the following items during the plate loading. • When the plate is being punched, the cam followers of the centering unit touch the plate sides. • The cam followers do not press against the plate
Plate
Centering unit
sides too hard. • The plate top side detection sensors are properly operating. 2) Check the following items for the wound plates. • Leading and trailing edge grip margins (Leading edge grip margin = 13.2 mm, Trailing edge grip margin = 7 mm 0, +0.1 mm) The values mentioned above are used for 0.3 mm plates. The thinner the plate is, the longer the trailing edge grip margin length will be. • The plate must touch the registration pins.
Registration pin
Trailing edge clamp
PT-R4300 SERVICE MANUAL
B-61
B.Installation 3051
3) Adjust the front sensor offset
Input parameter Machine option select
This adjustment is not necessary for the LH-PI
I/O Read/Write
plates, as it has been done at the factory.
Initialize data Special action ESC
OK
NEXT
4451
Centering test
→Execute Front sensor offset. →Select the plate type.
Adjust Displacement sensor NVRAM backup
→Press [START] to execute. →The offset value for the plate will be set.
NVRAM restore
OK
→Load a plate on the drum to confirm the plate edge hits the registration pins completely. →Go to the service maintenance mode. →Special action
Front sensor offset
ESC
Initialize the machine.
NEXT
Adjust the offset if the thickness is different just in case even though the same type of plate.
1150
1
0.15
2
0.20
3
0.24
4
0.30
5
Media Type 5
ESC
B-62
OK
NEXT
PT-R4300 SERVICE MANUAL
B.Installation 0300
4) Adjust the displacement sensor offset
Set printing machine Set plate
This adjustment is not necessary for the LH-PI
Set media type
plates, as it has been done at the factory.
Set exposure mode User maintenance ONLINE
OK
NEXT
1150
Initialize the machine. →Select the plate type. →Input -9.99 on Displacement offset. (This is the mode to get the offset.) →Load a plate.
1
0.15
2
0.20
3
0.24
4
0.30
5
Media Type 5
Adjust the offset if the thickness is different just in case even though the same type of plate.
ESC
OK
NEXT
1100
Comment Media Type 1
Posi
Nega
ESC
OK
Copy form
1101
CLR Thickness
0.24 mm
Front offset 0.00 Displancement offset -9.99 mm ESC
OK
PT-R4300 SERVICE MANUAL
7
8
9
4
5
6
1
2
3
0
• ENT
B-63
B.Installation 5) Y-lengthSince the sensor is at the rear side of the plate loaded on the drum, the sensor need not be re-adjusted to accommodate different types of plates used with the machine. Therefore, you do not need to re-adjust the sensor when the machine is installed.Readjust this sensor only when an error occurs with the plate length in the Y direction during plate loading on the drum, when the sensor is replaced with a new one, or when the position or angle of the sensor is adjusted. Even if the sensor has been adjusted (or the plate length has been recognized by the machine) properly, a plate length deviation within a ± 2.4 mm range is still allowed. 0300
Measure the plate length by scale and input this
Set printing machine Set plate
value at the plate setting. →Go to the user maintenance mode.
Set media type
→Test exposure →Hidden command (RH) for service engineer
Set exposure mode User maintenance ONLINE
OK
NEXT
→Input the password. →Hit OK key.
2000
ETC.
ESC
OK
2100
focus
zoom RH
ESC
OK
2180
CLR
Pass Word
7
8
9
4
5
6
1
2
3
0
•
0
ESC
B-64
OK
ENT
PT-R4300 SERVICE MANUAL
B.Installation 2181
No-Plate
Off
RH
Off
Full size
Off
ESC
OK
2182
Plate Length
CLR
0.0 mm
When you want to calibrate the plate length sensor, input the value of the correct plate size for Y direction. And load the measured plate. Normally save "zero".
ESC
→Input the actual measured value at the memory
7
8
9
view. →SAVE
4
5
6
→Wind the plate.
1
2
3
0
• ENT
SAVE
The plate is loaded on the drum without the registration punch when memorizing the length. At this moment,, the front sensor might get error. In this case change the parameter referring to the
2185
following procedure.
Save Data ? YES
ESC
NO
OK
Go to the service maintenance mode. →Input parameter →Drum position →Change the value of Front sensor. ( Increase about 5 pulses.) (The drum front check position shifts to counter clock wise when the Front sensor value is increased.) →Confirm the sensor lights are off after executing “Front check position” on Drum. →Memorize the plate again. →Set back the front sensor value.
PT-R4300 SERVICE MANUAL
B-65
B.Installation 4-6-3.Laser calibration 1) Write down the Iop values set for exposing images at 2000 and 2400 dpi. 2) You do not need to write down the values for resolutions whose Iop values have already been described in the factory set electric current data sheet. 3) Check whether the difference between the average operating current value (Iop value) set at the factory and the calibrated average operating current (calibrated Iop value) above is less then 50 mA. There is no problem when these values are almost equivalent. However, if the difference is significant, the optical axis may have deviated during transportation or condensation may have occurred. It is recommended that you should note down the calibration values when the service work is performed. This allows you to check the variation in the current values since the machine has been installed and helps you to find out the LDs that need to be replaced. 4) If there is no problem with the calibrated operating current, execute the calibration for the resolution at which the customer will expose images.
B-66
PT-R4300 SERVICE MANUAL
B.Installation 4-7.Exposure adjustment 0300
1) In the offline screen, select [User maintenance] and press [OK]. The screen shown in step 2) will appear.
Set printing machine Set plate Set media type Set exposure mode User maintenance
ONLINE
OK
NEXT
2) Select
2000
(test exposure) and press [OK]. The
screen shown in step 3) will appear.
ETC.
ESC
OK
3) Select the desired test exposure in the screen on the left, and perform exposure adjustment.
2100
focus
zoom RH
ESC
OK
focus
zoom
: Performs a test exposure to adjust the focus. (Refer to 4-7-1.) : Performs a test exposure to adjust the zoom. (Refer to 4-7-2.) : Performs a test exposure to adjust the light intensity. (Refer to 4-7-3.)
• Be sure to load the plate manually before performing a test exposure. • The printing machine and exposure condition settings are ignored when a test exposure or test pattern exposure is performed. • The start position for exposure in the primary scanning direction is approximately 25 mm from the bottom edge of the plate and the end position is approximately 25 mm from the top edge. Both positions are fixed. • When a positive-type plate is exposed, burn-out is not performed.
PT-R4300 SERVICE MANUAL
B-67
B.Installation 4-7-1.Adjusting the focus value 1) Load the plate manually.
2100
2) Select focus
focus
in the screen on the left and press [OK].
zoom RH
ESC
OK
Resolution key
Currently set value
2130
CLR
2400dpi (1920) Inital Value:[pulse] 2000
7
8
9
10
4
5
6
3
1
2
3
0
•
Inc.Value: [pulse]
Count:
0.0
Start Point:[mm] (0.0 - 830.0mm) ESC
OK
ENT
3) Enter values into the following fields. [Resolution key] Sets the resolution for the test exposure. The resolution changes each time the resolution key is pressed. Press the key until the desired resolution appears. [Currently set value] Displays the focus value (in pulse) currently set in “Set media type” data selected when the plate was loaded in the PT-R4300. For the focus adjustment, perform the test exposure with the following settings.
[Initial Value] [Inc. Value] (incremental value)
: Currently set value -100 : 10
[Count] : 21 [Start Point] (exposure start point) : Press [OK]. The screen shown in step 4) will appear. [Initial Value] The first focus value used in the test exposure. Allowable range: 101 to 4000 [Inc. Value] The amount of change from the initial value. Allowable range: 1 to 4000 [Count] The number of times the test exposure is to be performed. Allowable rage: 0 to 9999 [Start Point] Allowable range: 0.0 to 830.0
B-68
PT-R4300 SERVICE MANUAL
B.Installation
• The exposure start point is the distance from the plate edge to the point where the test exposure begins. This value is updated (moved to the next possible exposure position) each time a test exposure ends. (In this sequence, the exposure starting point is automatically recalculated by adding 5 mm to the last exposure end point.) • When performing a test exposure, the settings for the media type registered in the plate data that is selected when the plate is loaded are used for settings other than the initial value, incremental value, and count. 4) Check the displayed information and press [START]. The test exposure begins using the set in-
2131
2400dpi (1920) Initial Value: Inc.Value: Count: Start Point:
ESC
2000 pulse 10 pulse 3 0.0 mm
START
CANCEL
formation. When the test exposure is completed, the test exposure selection screen reappears.
The test exposure exposes the width that you set in [Plotting Width] and automatically inserts a 5 mm gap between exposures. 5) Manually unload and develop the plate. Check the exposure pattern strips with a magnifying glass and designate the focus value that satisfies the following conditions. When using a positive plate: • Shows the clearest Dot 0%. • Shows the sharpest Hor L&S 1. • Shows no unevenness for Dot 50%. When no differences can be found among the patterns, designate the focus value for the strip of the exposure patterns located at the median as the optimum focus value. Ten is subtracted from the optimum value to attain the actual set value to be used. When using a negative plate: • Shows the highest density for Dot 100%. When no differences can be found among the patterns, designate the focus value for the strip of the exposure patterns located at the median as the optimum focus value. Ten is subtracted from the optimum value to attain the actual set value to be used.
For details of the names and the types of each exposure pattern, refer to “4-7-5 Test exposure”. PT-R4300 SERVICE MANUAL
B-69
B.Installation The actual set value of the focus should be rounded up to the nearest multiple of 5. 6) Following the same procedures, designate the focus values for the other resolutions and plates.
Factory set value
B-70
PT-R4300 SERVICE MANUAL
B.Installation 4-7-2.Adjusting the zoom value 1) Load the plate manually. 2) Select
2100
focus
zoom
‚ in the screen on the left and press [OK].
zoom RH
ESC
OK
Resolution key
Currently set value
2140
CLR
2400dpi (1000) Inital Value: [pulse] 900 Inc.Value:
[pulse]
ESC
10
3
Count: Start Point:[mm] (0.0 - 830.0)
3) Enter values into the following fields. [Resolution key]
7
8
9
4
5
6
1
2
3
0
•
0.0
OK
Sets the resolution for the test exposure. The resolution changes each time the resolution key is pressed. Press the key until the desired resolution appears. [Currently set value] Displays the zoom value (in pulse) currently set
ENT
in “Set media type” data selected when the plate was loaded in the PT-R4300. For the zoom adjustment, perform the test exposure with the following settings.
[Initial Value] [Inc. Value] (incremental value)
: Currently set value -350 : 50
[Count] : 15 [Start Point] (exposure start point) : Press [OK]. The screen shown in step 4) will appear. [Initial Value] The first zoom value used in the test exposure. Allowable range: 201 to 9970 [Inc. Value] The amount of change from the initial value. Allowable range: 1 to 9970 [Count] The number of times the test exposure is to be performed. Allowable rage: 0 to 9999 [Start Point] Allowable range: 0.0 to 830.0
PT-R4300 SERVICE MANUAL
B-71
B.Installation
• The exposure start point is the distance from the plate edge to the point where the test exposure begins. This value is updated (moved to the next possible exposure position) each time a test exposure ends. (In this sequence, the exposure starting point is automatically recalculated by adding 5 mm to the last exposure end point.) • When performing a test exposure, the settings for the media type registered in the plate data that is selected when the plate is loaded are used for settings other than the initial value, incremental value, and count. 4) Check the displayed information and press [START]. The test exposure begins using the set in-
2141
2400dpi (1920) Initial Value: Inc.Value: Count: Start Point:
ESC
2000 pulse 10 pulse 3 0.0 mm
START
CANCEL
formation. When the test exposure is completed, the test exposure selection screen reappears.
The test exposure exposes the width that you set in [Plotting Width] and automatically inserts a 5 mm gap between exposures.
B-72
PT-R4300 SERVICE MANUAL
B.Installation Horizontal lines are consistently straight.
Ch29 Ch30 Ch31
Ch0 Ch1 Ch2
There are not many vertical lines which are uneven or of inconsistent thickness.
5) Manually unload and develop the plate. Check the exposure pattern strips with a magnifying glass and designate the zoom value that satisfies the following condition. • Shows the most straight lines for Hor L&S 2. When no differences can be found among the patterns, designate the zoom value for the strip of the exposure patterns located at the median as the zoom set value. For details of the names and the types of each exposure pattern, refer to “4-7-5 Test exposure”. The actual set value of the zoom should be rounded up to the nearest multiple of 5. 6) Following the same procedures, designate the zoom values for the other resolutions and plates.
C1 pattern
PT-R4300 SERVICE MANUAL
B-73
B.Installation 4-7-3.Adjusting the light intensity
Use the light intensity value that is set for each media type (manufacturer, model number, thickness). 1) Load the plate manually.
2100
2) Select focus
in the screen on the left and press [OK].
zoom RH
ESC
OK
Resolution key
Currently set value
3) Enter values into the following fields. [Resolution key]
2110
CLR
2400dpi (80.0) 5.0
Inc.Value:[%]
3
Count:
8
9
4
5
6
1
2
3
0
•
Sets the resolution for the test exposure. The resolution changes each time the resolution key is pressed. Press the key until the desired resolution appears. [Currently set value]
0.0
Start Point:[mm] (0.0 - 830.0) ESC
7
50.0
Initial Value:[%]
OK
ENT
Displays the light intensity value (in %) currently set in “Set media type” data selected when the plate was loaded in the PT-R4300. For the light intensity adjustment, perform the test exposure with the following settings.
[Initial Value] : 40 onward [Inc. Value] (incremental value) : 5 [Count]
: 13
Press [OK]. The screen shown in step 4) will appear. [Initial Value] The first light intensity value used in the test exposure. Allowable range: 10.0 to 100.0 [Inc. Value] The amount of change from the initial value. Allowable range: 1.0 to 100.0 [Count] The number of times the test exposure is to be performed. Allowable rage: 0 to 9999 [Start Point] Allowable range: 0.0 to 830.0
B-74
PT-R4300 SERVICE MANUAL
B.Installation
• The exposure start point is the distance from the plate edge to the point where the test exposure begins. This value is updated (moved to the next possible exposure position) each time a test exposure ends. (In this sequence, the exposure starting point is automatically recalculated by adding 5 mm to the last exposure endpoint.) • When performing a test exposure, the settings for the media type registered in the plate data that is selected when the plate is loaded are used for settings other than the initial value, incremental value, and count. 4) Check the displayed information and press [START]. The test exposure begins using the set in-
2111
2400dpi (80.0) InitialValue: 50.0 % 5.0 % Inc.Value: 3 Count: 0.0 mm Start Point: mm Plotting Width: 20 ESC
START
formation. When the test exposure is completed, the test exposure selection screen reappears.
CANCEL
The test exposure exposes the width that you set in [Plotting Width] and automatically inserts a 5 mm gap between exposures. 5) Manually unload and develop the plate. Check the strips of exposure patterns with a magnifier and designate the light intensity set value that satisfies the following condition. • Multiply the value of the strip of test patterns that shows the clearest Dot 0% by 1.4 to 1.6 times. The actual set value of the light intensity should be rounded up to the nearest whole number. 6) Following the same procedures, designate the light intensity values for the other resolutions and plates.
4-7-4.Saving the data Following the procedures in “4-5-2 Setting the media type”, save the focus, zoom and light intensity values that are designated in 4-7-1 to 4-7-3 for each media type.
PT-R4300 SERVICE MANUAL
B-75
B.Installation 4-7-5.Test exposure To check the data that are saved, perform a test exposure. 1) Load the plate manually.
2100
2) Select focus
in the screen on the left and press [OK].
zoom RH
ESC
OK
Test pattern selection key
Resolution key 2170
CLR
2400dpi Pattern:
8
9
4
5
6
1
2
3
0
•
C1
Plotting Width: (5.0 - 830.0 [mm]) Start Point: (0.0 - 830.0 [mm])
ESC
7
50.0 0.0
OK
ENT
3) Enter values into the following fields. [Resolution key] Sets the resolution for the test exposure. The resolution changes each time the resolution key is pressed. Press the key until the desired resolution appears. [Test pattern selection key] Selects the test pattern. The test pattern changes each time the test pattern selection key is pressed. Press the key until the desired test pattern appears. For the type of test pattern, refer to the description below. [Plotting Width] The exposure width of the test pattern. Allowable range: 5.0 to 830.0 [Start Point] Allowable range: 0.0 to 830.0
• The exposure start point is the distance from the plate edge to the point where the test exposure begins. This value is updated (moved to the next possible exposure position) each time a test exposure ends. (In this sequence, the exposure starting point is automatically recalculated by adding 5 mm to the last exposure end point.) • When performing a test exposure, the settings for the media type registered in the plate data that is selected when the plate is loaded are used for settings other than the initial value, incremental value, and count. B-76
PT-R4300 SERVICE MANUAL
B.Installation Press [OK]. The screen show in step 4) will appear.
2171
4) Check the displayed information and press
2400dpi
[START]. The test exposure begins using the set information.
C1 Pattern: Plotting Width: 50.0 0.0 mm Start Point:
ESC
START
When the test exposure is completed, the test exposure selection screen reappears. CANCEL
5) Manually unload and develop the plate. Check if there is any problem with the exposed results.
PT-R4300 SERVICE MANUAL
B-77
B.Installation Test pattern list Pattern name Dot 0% Dot 3% Dot 5% Dot 10% Dot 15% Dot 50% Dot 85% Dot 90% Dot 95% Dot 97% Dot 100% Grid
C1 D1 AUX1 AUX2 AUX3 AUX4 CHO-31 Hor L&S 1 Hor L&S 2 Ver L&S 1 Ver L&S 2
B-78
Dot% 0% 3% 5% 10% 15% 50% 85% 90% 95% 97% 100%
Dot angle 45
Line number/pitch 4000 dpi: 250 line/inch 2400 dpi: 150 line/inch 2000 dpi: 125 line/inch 1200 dpi: 75 line/inch 2540 dpi: 159 line/inch 2438 dpi: 152 line/inch
Remarks Pseudo dots
4000 dpi: 1.63 1.52 mm Grid pattern 2400 dpi: 2.71 2.54 mm 2000 dpi: 3.25 3.05 mm 1200 dpi: 5.42 5.08 mm 2540 dpi: 2.56 2.40 mm 2438 dpi: 2.67 2.50 mm Continuous exposure of C1 pattern Continuous exposure of C1 pattern Not used Not used Not used Not used To allow verification of the light intensity balance of each laser channel (ch 0 through ch 31), a solid is exposed with each channel. Horizontal direction 1 line - 1 space Lines and spaces Horizontal direction 2 lines - 2 spaces Vertical direction 1 line - 1 space Vertical direction 2 lines - 2 spaces
PT-R4300 SERVICE MANUAL
B.Installation a
256pixel
a
240pixel
Pseudo dots a
a
a
Grid pattern
Lines and spaces (1 line, 1 space)
a
Primary scanning direction Lines and spaces (2 lines, 2spaces)
7
15
23
31
6
14
22
30
5
13
21
29
4
12
20
28
3
11
19
27
2
10
18
26
1
9
17
25
0
8
16
24
Expose original point Secondary scanning direction Ch0 through ch31 pattern exposure
C1 pattern
PT-R4300 SERVICE MANUAL
D1 pattern
B-79
B.Installation 4-7-6.Other test exposure methods In addition to the test exposures described above, test exposures for simultaneous adjustment of focus and zoom, and for simultaneous adjustment of light intensity and drum rpm can be performed in the PT-R4300. 1) Select
2100
or
in the screen on the left and press
[OK]. : Test exposure for simultaneous adjustment of focus
zoom
focus and zoom : Test exposure for simultaneous adjustment of
RH
light intensity and drum rpm 2) When is selected, the screen on the left appears. ESC
OK
When appears. Currently set value
Resolution key 2160
CLR
2400dpi (2280, 6450) Initial Value: 2000 4985 [puls] Inc.Value: 50 20 [puls] 8 7 Count: Start Point: (0.0 ~ 1030.0 [mm])
ESC
0.0
OK
7
8
9
4
5
6
1
2
3
0
• ENT
is selected, the screen on the next page
Enter values into the following fields. [Resolution key] Sets the resolution for the test exposure. The resolution changes each time the resolution key is pressed. Press the key until the desired resolution appears. [Currently set value] Displays the focus value (in pulse) and the zoom value (in pulse) currently set in the “Set media type” data selected when the plate was loaded in the PT-R4300. [Initial Value]: The first focus value and zoom value used in the test exposure. Allowable range: 201 to 9970 Allowable range: 101 to 4000 [Inc. Value] (incremental value): The amount of change from initial values Allowable range: 1 to 9970 Allowable range: 1 to 4000 [Count]: The number of times the test exposure is to be performed. Allowable rage: 0 to 9999 [Start Point] Allowable range: 0.0 to 830.0
B-80
PT-R4300 SERVICE MANUAL
B.Installation Resolution key
Currently set value
2150
CLR
2400dpi (700, 75.0) Initial Value: 650 50.0 [rpm],[%] Inc.Value 25 2.0 [rpm],[%] Count: 9 10 Start Point: 0.0 (0.0 ~ 1030.0 [mm])
ESC
OK
7
8
9
4
5
6
1
2
3
0
• ENT
[Resolution key] Sets the resolution for the test exposure. The resolution changes each time the resolution key is pressed. Press the key until the desired resolution appears. [Currently set value] Displays the light intensity value (in %) and the drum rpm (in rpm) currently set in “Set media type” data selected when the plate was loaded in the PT-R4300. [Initial Value]: The first light intensity value and drum rpm value used in the test exposure. Allowable range: 100 to 1000 Allowable range: 10.0 to 100.0 [Inc. Value] (incremental value): The amount of change from initial values Allowable range: 1 to 1000 Allowable range: 1.0 to 100.0 [Count]: The number of times the test exposure is to be performed. Allowable rage: 0 to 9999 [Start Point] Allowable range: 0.0 to 830.0
• The exposure start point is the distance from the plate edge to the point where the test exposure begins. This value is updated (moved to the next possible exposure position) each time a test exposure ends. (In this sequence, the exposure starting point is automatically recalculated by adding 5 mm to the last exposure end point.) • When performing a test exposure, the settings for the media type registered in the plate data that is selected when the plate is loaded are used for settings other than the initial value, incremental value, and count.
Please note the following whenever you enter a parameter value. • Set the initial value higher than the lower limit for each parameter. • Values calculated by the formula “Initial Value + Inc. Value x (Count - 1)” should be lower than the upper limit for each parameter. • Values calculated by the formula “Start Point + 35 x (Count set for the secondary direction - 1)” should be less than the plate size in the secondary direction. • Values calculated by the formula “Start Point + 100 x (Count set for the primary direction -1)” should be less than the plate size in the primary direction minus 40 mm. PT-R4300 SERVICE MANUAL
B-81
B.Installation 3) When
2161
2400dpi (2280) (6450) Initial Value: 2000 puls 4985 puls 50 puls 20 puls Inc.Value: 8 7 Count: Start Point: 0.0 mm
ESC
START
is selected, the upper screen appears.
When is selected, the lower screen appears. Check the displayed information and press [START].
CANCEL
2151
2400dpi (700) (75.0) Initial Value: 650 rpm 50.0 % 25 rpm Inc.Value: 2.0 % 9 Count: 10 Start Point: 0.0 mm
ESC
START
CANCEL
Zoom is incremented.
Drum rpm is incremented. 30mm
30mm
6050pulse
650rpm
95mm
5mm
5mm
Focus is incremented.
6000pulse 5mm
2000pulse 2020pulse
: Test exposure for simultaneous adjustment of focus and zoom
B-82
95mm
Light intensity is incremented.
600rpm 5mm
50% 55%
: Test exposure for simultaneous adjustment of light intensity and drum rpm
PT-R4300 SERVICE MANUAL
B.Installation 4-8.Other settings 4-8-1.Setting the exposure maintenance 0300
1) In the offline screen, select [User maintenance] and press [OK]. The screen shown in step 2) will appear.
Set printing machine Set plate Set media type Set exposure mode User maintenance
ONLINE
OK
NEXT
2) Select
2000
‚ and press [OK] in the screen on the left.
The screen shown in step 3) will appear.
ETC.
ESC
OK
and press [OK] in the screen on the left. 3) Select The screen shown in step 4) will appear.
2100
RH
focus
zoom RH
ESC
OK
2180
CLR
Pass Word
7
8
9
4
5
6
1
2
3
0
•
0
ESC
OK
PT-R4300 SERVICE MANUAL
4) Enter the password shown below in the screen on the left. Password: 4000 or 4300 The screen shown in step 5) will appear.
ENT
B-83
B.Installation 5) Set the following commands.
2181
No-Plate
Off
RH
Off
Full size
[No-Plate] Allows you to check all the exposure sequences without loading a plate into the machine. For usual operation: OFF
Off
ESC
OK
The commands set here are effective only when they are executed from the host computer. The commands are ignored during test exposure in the PT-R4300. RH
: Allows you to operate the PT-R4300 without lighting up the LD (laser diodes) in the recording head.
For usual operation: OFF [Full size]: Allows you to perform exposures including the grip margins. For usual operation: OFF 2182
Plate Length
CLR
0.0 mm
When you want to calibrate the plate length sensor, input the value of the correct plate size for Y direction. And load the measured plate. Normally save "zero".
ESC
7
8
9
4
5
6
1
2
3
0
•
ning direction and the secondary scanning direction. For details about teaching the PT-R4300 the plate length and width for plate detection, refer to page B65.
7) Press [YES] and then [OK] to save the data.
Save Data ? YES
B-84
fields so that the PT-R4300 will recognize the length and width when detecting plates in the primary scan-
ENT
SAVE
2185
ESC
6) Enter values into the plate length and plate width
NO
If you want to cancel the save, press [NO] and then [OK]. Pressing [ESC] returns you to the screen shown in step 6).
OK
PT-R4300 SERVICE MANUAL
B.Installation 4-8-2.User settings 0300
1) In the offline screen, select [User maintenance] and press [OK]. The screen shown in step 2) will appear.
Set printing machine Set plate Set media type Set exposure mode User maintenance
ONLINE
OK
NEXT
2) Select [ETC.] and press [OK] in the screen on the
2000
left. The screen shown in step 3) will appear.
ETC.
ESC
2200
OK
3) [Set Date Time] Sets the date and time.
Set Date Time Punch for cleaning
[Punch for cleaning] Operates the punch.
Consumable Timer
[Laser calibration] Calibrates the laser in the recording head.
Language Laser power measure ESC
OK
NEXT
[Consumable Timer] Checks the running time of the PT-R4300 and sets the consumable timers. [Language] Sets the language used in the display. [Laser power measure] Measures the laser power. [Cancel calibration] Cancels the calibration results and restores the original status.
PT-R4300 SERVICE MANUAL
B-85
B.Installation 2201
[Laser calibration]
Laser calibration
Calibrates the laser. Refer to “3-7-4 Laser Calibration screen” in chapter D. The screen is shared
Cancel calibration Calibration info.
by the User Maintenance and the Maintenance screens.
Return error to host Option setting ESC
OK
NEXT
[Calibration info.] Displays the calibration information. [Return error to host] Sends the error information to the host computer. [Option setting] Allows the setting of the options that can be accessed by customers.
(1) Set Date/Time 2200
1) Select [Set Date Time] and press [OK] in the screen
Set Date Time
on the left. The screen shown in step 2) will appear. Punch for cleaning Consumable Timer Language Laser power measure ESC
OK
NEXT
2210
CLR Year/Month/Day 2001
6
1
7
8
9
4
5
6
1
2
3
0
•
2) Check or enter the date and press [SAVE]. The screen shown in step 3) will appear.
Time 10: 10
ESC
ENT
SAVE
3) Press [YES] and then [OK] to save the data.
2215
Save Data ? YES
ESC
B-86
NO
If you want to cancel the save, press [NO] and then [OK]. Pressing [ESC] returns you to the screen shown in step 2).
OK
PT-R4300 SERVICE MANUAL
B.Installation (2) Punch for cleaning 2200
1) Select [Punch for cleaning] and press [OK] in the screen on the left. The screen shown in step 2) will
Set Date Time Punch for cleaning
appear.
Consumable Timer Language Laser power measure ESC
OK
NEXT
2) Press [OK] to start operating all punches. Pressing [ESC] or [Cancel] returns you to the screen shown in
2270
step 1).
Start OK ?
ESC
OK
PT-R4300 SERVICE MANUAL
Cancel
B-87
B.Installation (3) Cosumable Timer 2200
1) Select [Consumable Timer] and press [OK] in the screen on the left. The screen shown in step 2) will
Set Date Time Punch for cleaning
appear.
Consumable Timer Language Laser power measure ESC
OK
NEXT
2) Check or enter values into the following fields. Running time:
2240
Running time 0h Actual running time
The total time the power has been ON. Actual running time:
0h Exposure time 0h
The time the PT-R4300 has actually been in operation.
Plate winding cycles 0 ESC
SAVE
NEXT
Exposure time: The amount of time exposure has been performed. Plate winding cycles:
NEXT
The number of times plates have been loaded. Exterior cover filter:
2241
Exterior cover filter (Max:1000h) 78 h Clamp cycles (MAX:20000) 786 Plate winding cycles/ye 786
RESET
The usage time of the external cover filter. When the running time reaches the maximum time (1000 hours), a message appears telling you to replace the external cover filter. After replacing the external cover filter, press [RESET] to reset the usage time to “0 h”.
ESC
SAVE
NEXT
2242
Punch cycles (Max:10000) Punch cycles (Max:10000) Punch cycles (Max:10000) Punch cycles (Max:10000)
No.1
ESC
SAVE
Clamp cycles: The number of the clamp operations. When the accumulated count reaches the maximum (20000), a message appears telling you to replace
78 No.2
the clamps. Plate winding cycles/ye:
78 No.3 78 No.4
The number of plate winding operations within a year.
78 NEXT
Punch cycles No. 1 to 8: The number of punch operations. When the accumulated count reaches the maximum (10000), a message appears telling you to replace the punches.
B-88
PT-R4300 SERVICE MANUAL
B.Installation 3) Press [YES] and then [OK] to save the data.
2245
If you want to cancel the save, press [NO] and then [OK].
Save Data ? YES
ESC
Pressing [ESC] returns you to the screen shown in step 2).
NO
OK
(4) Language 2200
1) Select [Language] and press [OK] in the screen on
Set Date Time
the left. The screen shown in step 2) will appear.
Punch for cleaning Consumable Timer Language Laser power measure ESC
OK
2250
NEXT
2) Select the desired language and press [OK]. The
English Japanese
screen shown in step 3) will appear.
AUX
ESC
OK
3) Press [YES] and then [OK] to save the data.
2255
Save Data ? YES
ESC
NO
If you want to cancel the save, press [NO] and then [OK]. Pressing [ESC] returns you to the screen shown in step 2).
OK
PT-R4300 SERVICE MANUAL
B-89
B.Installation (5) Laser power measure 2200
[Laser power measure]
Set Date Time
Measures the laser output. Select [Laser power measure] and press [OK] in
Punch for cleaning Consumable Timer
the screen on the left. The screen to select the resolution will appear.
Language
Pressing [ESC] returns you to the upper layer Menu screen.
Laser power measure ESC
OK
NEXT
Select the resolution for measuring the laser power and press [OK].
2260
Resolution
ESC
1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
The screen for laser output measurement will appear.
OK
Press [OK] to execute the laser power measurement.
2261
Start OK ?
ESC
OK
During the laser power measurement, the screen
2262
shown on the left is displayed. Once the laser output measurement has been Processing Now. Please wait !
B-90
completed, the screen shown next will appear.
PT-R4300 SERVICE MANUAL
B.Installation After completing the laser power measurement,
2263
0ch 1ch 2ch 3ch 4ch 5ch 6ch 7ch
100% 8ch 100% 9ch 100% 10ch 100% 11ch 100% 12ch 100% 13ch 100% 14ch 100% 15ch
100% 100% 100% 100% 100% 100% 100% 100%
16ch 17ch 18ch 19ch 20ch 21ch 22ch 23ch
100% 100% 100% 100% 100% 100% 100% 100%
24ch 25ch 26ch 27ch 28ch 29ch 30ch 31ch
the screen shown on the left is displayed. This screen indicates, in percentage, the laser power of
100% 100% 100% 100% 100% 100% 100% 100%
each channel with respect to the target light intensity. The standard target light intensities are as noted below.
OK
These values have been specified in the Laser power setting screen, which is accessible by selecting Service Maintenance → Input parameter → RH parameter. 1200 dpi: 240 mW/ch 2400 dpi: 240 mW/ch
2000 dpi: 270 mW/ch 2438 dpi: 240 mW/ch
2540 dpi: 230 mW/ch 4000 dpi: 240 mW/ch The measured values are indicated in mW in the service mode screen. Pressing [OK] brings up the screen shown on the left. In this screen, you can check whether the
2264
0 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31
cables running from the main unit to the recording head are not disconnected.
× OK
: When the measured light intensity is 50% or more of the target light intensity. : When the measured light intensity is less
than 50% of the target light intensity. The measured values are indicated in % in the service mode screen.
1) Operation conditions The screen to check for the disconnection of image signal cables between the RB31 board and the recording head is displayed when the following conditions are satisfied. • The firmware version of the main unit is: PT-R4000 : Ver. 3.06 or higher PT-R4000II : Ver. 4.04 or higher PT-R4300 : Ver. 1.00 or higher • A plate has been loaded. • The Machine Type 2 parameter (Service Maintenance → Set misc. data) has been set to “4”. (Factory set value: 0) • The 16 ch exposure mode has not been set. 1) There is no disabled or lowered light intensity LD. 2) The 16 ch exposure mode has not been selected in the Service Maintenance → Machine option select screen. PT-R4300 SERVICE MANUAL
B-91
B.Installation 2) Description of the operation The cable disconnection is checked by issuing a pseudo-image signal from the RB31 board to light up the LDs. The light intensity of each LD is measured using the calibration sensor. When the measured LD power is insufficient, the sensor identifies it as a cable disconnection. The check for cable disconnection can be performed only when the recording head is in the calibration position. 3) Timing of the check The cable disconnection check timing is: • After the regular light intensity measurement 1) Before exposing the first plate after turning ON the power supply 2) Before exposing a plate after completing exposure of 24 plates (default value) Note that if the output laser power of any of the LDs is out of the ± 5% (default value) range of the target output value, the cable disconnection will not be checked. 4) When the disconnection of any cable between the RB31 board and the recording head is detected: If the output laser power of any of the LDs is less than 50% of its target value, the following error will be issued. Ex839 The cable between RB31 board and recording head is disconnected. When this error is issued, the exposure operation is canceled and it can be resumed after resetting the error and performing an initialization.
B-92
PT-R4300 SERVICE MANUAL
B.Installation (6) Cancel calibration 2201
[Cancel calibration]
Laser calibration
It cancels the laser calibration result and returns to the original status.
Cancel calibration Calibration info.
In “User Settings” screen, select [Cancel calibration] and hit [OK], and then the resolution selec-
Return error to host
tion screen is displayed.
Option setting
[ESC] ESC
OK
NEXT
Returns to “User Settings” screen. Select the resolution that you would like to cancel
2280
Resolution 1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
the calibration, and hit [OK]. The calibration cancellation screen is displayed.
OK
2281
The date when the calibration is performed and its status are displayed past 5 times.
1
9/20 15:35 32ch 100%
2
9/10 10:15 32ch 100%
3
8/20 13:35 32ch 100% E0816
Select the calibration number that you would like to return and hit the key. The confirmation of
4
8/15 19:35 32ch 100%
calibration cancellation screen is displayed.
5
ESC
OK
Press [OK] to execute the laser power measure-
2282
ment. Start OK ? YES
ESC
NO
OK
The left screen is displayed during performing. It returns to “User Settings” screen after the pro-
2283
cessing is completed. Processing Now Please wait !
PT-R4300 SERVICE MANUAL
B-93
B.Installation (7) Calibration info. 2201
1) Select [Calibration info.] and press [OK] in the screen on the left. The screen shown in step 2) will
Laser calibration Cancel calibration
appear.
Calibration info. Return error to host Option setting ESC
OK
NEXT
2) The calibration information will appear. Pressing [ESC] returns you to the screen shown in step 1).
[Calibration period] Displays the total time from the start of exposure until automatic calibration is performed. (Usually every 16 hours) [Time to next calibration] Displays the exposure time remaining until the next automatic calibration. [Reso] Displays resolutions. [Channel] 32ch: 0 to 15ch:
Indicates that the 32 laser diode channels are calibrated for exposure. Indicates that laser diode channels 0 to 15 are calibrated for exposure as some of channels 16 to 31 cannot be calibrated to a specific light intensity.
16 to 31ch: Indicates that laser diode channels 16 to 31 are calibrated for exposure as some of channels 0 to 15 cannot be calibrated to a specific light intensity. [Pow.] Displays the percentage of light intensity to which the laser diodes have been calibrated relative to the preset light intensity value, which is regarded as 100%. Usually the calibrated value should be 100%. When the value displayed here is less than 100%, it indicates that there are some channels that cannot be calibrated to the same value as the preset light intensity and so the channels are calibrated to a lower light intensity than the preset light intensity. However, the laser diodes are calibrated to a higher light intensity than the value preset in the media type setting, therefore this will have no effect on exposure quality. When “???” is displayed, it indicates that the calibration is not performed normally.
B-94
PT-R4300 SERVICE MANUAL
B.Installation [Cal.] Displays [req.] until calibration is performed after exposure is completed for the time displayed in [Calibration period] and also when calibration is required. Displays [done] when calibration is performed. [Warning] Displays the code of any warning/error that occurs while calibration is being performed. Displays nothing when calibration is performed normally. (8) Return error to host Exposure cannot be interrupted from the host computer. Therefore, the interruption command is sent to the host computer when the power of the main unit is turned OFF during exposure. 2201
1) Select [Return error to host] and press [OK] in the
Laser calibration
screen on the left. The screen shown in step 2) will appear.
Cancel calibration Calibration info. Return error to host Option setting ESC
OK
NEXT
2) Press [OK] to send an error to the host computer. Pressing [ESC] or [Cancel] returns you to the screen
2270
shown in step 1).
Start OK ?
ESC
OK
PT-R4300 SERVICE MANUAL
Cancel
B-95
B.Installation (9) Option setting 2201
1) Select [Option setting] and press [OK] in the screen on the left. The screen shown in step 2) will appear.
Laser calibration Cancel calibration Calibration info. Return error to host Option setting ESC
OK
NEXT
2) Press [SAVE] to save the data. Pressing [ESC] returns you to the screen shown in step 1). [Buzzer while trans] Buzzer for rear unloading ON/OFF /LOUD [Mistake plate] Plate that is loaded incorrectly Remove/Discharge [Inter leaf warning] Warning of interleaf discharge OFF/10 sheets/.../90 sheets/100 sheets [Preload button] ON/OFF/COUNTER [Empty warning] Warning that no plates remain ON/OFF
B-96
PT-R4300 SERVICE MANUAL
B.Installation 4-9.Exposure check 1) Perform a test exposure with the plate sizes to be used by the customer following the illustration below. Use the test patterns 0% and 50% from the Home side to the Away side, and set [Full size] to ON. Make sure that there is no plate looseness and also check the grip margins. The following illustrates the use of a positive-type plate. (For details of adjustment procedures.)
50%
0%
100mm
50%
100mm
2) Perform a full size plate exposure using the Grid pattern and check for any slanting of the image. (For details of the adjustment parameter.) 3) Perform an exposure via the RIP and check the exposed image with the items described below. • Starting point for image exposure (For details of the adjustment parameter.) • Image position relative to plate (For details of the adjustment parameter.) • Checking of effective image area (grip margins 12 mm/8 mm) (For details of the adjustment parameter.) 4) When attaching the punch system for printing machine (optional punch), check the edge of plate and the horizontal position of the punch.
PT-R4300 SERVICE MANUAL
B-97
B.Installation
5.Punch attachment (option) 5-1.Attachment The PT-R4300 can optionally incorporate up to four punches, including five punch types in addition to the registration punch. Customer’s should attach the optional punches.If optional punches are provided with the PT-R4300, attach them following the procedure described below. Bacher 220, 425 DS 400, 500 Protocol 458 Heidel Komori
425, 393 550
Maximum attachable punch number: 4 punches 1) Punch set check Confirm that all required parts, such as punches, bases, parallel pins, attachment screws and tilt pins, are set. (The figure on the left shows a Heidel punch set.)
2) Punch attachment to the base After confirming the punch front margin the customer uses, insert parallel pins into the base holes and mount a punch block on them.The base can be used with either side up. A base whose upper surface shows an “H” mark should be used on the Home
Parallel pin
Magnet sensor
side, and one with an “A” mark should be used on the Away side. 3) Magnet sensor attachment Attach punch magnet sensors facing the marked side up.
• Be sure to insert the magnet sensors to the furthest end. Ser.NO
Punch No.
• When you adjust the sensor, ensure that the punches are not extended by executing an Actuator test.
B-98
PT-R4300 SERVICE MANUAL
B.Installation 4) Punch attachment to the main unit Make sure that no dirt or scratches are found on the main unit’s punch attachment bases before attaching
Pins
the punches.When attaching the punches, make sure that they touch the pin stoppers on the main unit side.
• Check the type of optional punch that the cus-
No dirt or scratches on the attachment surface (also on the punch side)
tomer will use as the required margin at the edge of a plate may vary depending on the punch type. • Always turn OFF the power to the main unit during the punch attachment.
When the punch is attached (Home side)
When the punch in attached (Away side)
5) Connecting connectors Connect the connectors for motors and sensors. The connectors are numbered 1, 2, 3, 4, 5 and 6 from the Home side. (Registration punches are always connected to Nos. 3 and 4.) Be careful not to misunderstand the relationships between actual punch attachment positions and connector numbers.The motor connectors are marked “M”.
PT-R4300 with punches attached
PT-R4300 SERVICE MANUAL
B-99
B.Installation 5-2.Setting the punch name (Service menu) Punch settings can be made on the main unit with the procedure described below.
0301
1) Turn ON the power to the main unit, select [Service] and then press [OK]. (Password:
Infomation Set punch name
4000or 4300)
Service ONLINE
3051
OK
NEXT
2) Select Machine option select and press [OK].
Input parameter Machine option select I/O Read/Write Initialize data Special action
ESC
3706
OK
NEXT
3) Set Punch to ON and press [SAVE].
Punch adjust Calibration position Set punch data RH parameter Drum parameter
ESC
B-100
OK
NEXT
PT-R4300 SERVICE MANUAL
B.Installation 3880 No.1
Block 0
Width 0
No.2
0
0
No.3
0
0
No.4
0
0
No.5
0
0
No.6
0
0
No.7
0
0
No.8
0
0
No.9
0
ESC
3880
B
7
8
9
C
4
5
6
D
1
2
3
0
E
0
•
SAVE
F
A
No.1
Block 0
Width 0
No.2
0
0
No.3
0
0
No.4
0
0
No.5
0
0
No.6
0
0
No.7
0
0
No.8
0
0
No.9
0
ESC
CLR
A
punch number and enter the connector numbers to which the punches are connected, then press the [ENT] key.For example, when you wish to attach the punches to the connectors Nos. 2 and 5, enter “25”. Enter “25” in this field, for example.
ENT
CLR
B
7
8
9
C
4
5
6
D
1
2
3
0
E
0
•
SAVE
F
PT-R4300 SERVICE MANUAL
4) Move the cursor to the Block field next to the
5) Enter the punch width in the Width field and press the [ENT] key, then press [SAVE]. Enter “425” in this field, for example.
ENT
B-101
B.Installation 5-3.Setting the punch name (Main menu) If optional punch units are installed in the PT-R4300, service personnel will register the name of each punch unit as one of the punch options (from 1 to 9) on the screen so that you can select and use it more easily. The punch name-setting screen also displays the punch unit’s registered pitch in the Maintenance screen. Although a punch option can be used without registering its name, be sure to register a name for each option to facilitate punch unit selection during printing machine setting. 0300
1) In the offline screen, press [NEXT]. The screen
Set printing machine
shown in step 2) will appear. Set plate Set media type Set exposure mode User maintenance ONLINE
OK
NEXT
2) Select [Set punch name] and press [OK]. The punch
0301
name setting screen shown in step 3) will appear. Infomation Set punch name Service ONLINE
OK
NEXT
1200
1
Punch 1
780 mm
2
Punch 2
425 mm
3
Punch 3
0 mm
4
Punch 4
0 mm
5
Punch 5
0 mm
ESC
OK
3) Select the number that you intend to set a punch name and press [OK]. The screen shown in step 4) will appear.
NEXT
Punch pitch
B-102
PT-R4300 SERVICE MANUAL
B.Installation ESC @
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
]
^
CLR
SPC
4) Enter a name for a punch (e.g., Bacher 780 mm) in the screen on the left. Flips through the entry screens for upper case letters, lower case letters, and symbols/numbers. BS
BS
ENT CLR SPC
Moves the cursor. Deletes the letter to the left of the cursor. Clears the entered comment. Enters a space.
Returns to the screen shown in step 3). After entering a comment, press [ESC]. The screen ESC
shown in step 5) will appear. 5) Press [YES] and then [OK] to save the data. If you want to cancel the save, press [NO] and then
1158
Save Data ? YES
ESC
NO
[OK]. Pressing [ESC] returns you to the screen shown in step 3).
OK
PT-R4300 SERVICE MANUAL
B-103
B.Installation 5-4.Tilt correction method • Required items Bacher register pins Parts code: 030100072 Name: Register pin P la te φ6
.3 5
Loupe 1) Have two plates with punched holes ready. Turn OFF the power to the PT-R4300 and remove the rear cover.
E m u ls io n s u rfa c e
2) Set these plates with their emulsion surfaces facing each other as shown in the figure on the left and slide the Bacher register pins into the registration pin B a c h e r re g is te r p in ( φ 6 .3 5 )
A
holes (round). 3) Using a loupe (10x), measure the difference between the layered outer punch holes (indicated as “A” in the figure on the left) to check the deviation of these plates. Correct the measured deviation (A) following the procedure described below.
S to p p e r p in
S to p p e r p in
4) Assume that the measured deviation (A) was 50 µm. As the deviation can be corrected by shifting the Home-side punch by 50 µm, remove the punch on which the Home-side option punch is attached and
S id e s to p p e r p in
T e m p la te
replace the parallel pins (stopper pins) with tilt pins with a 4.9 mm outer diameter.
A w a y-s id e o p tio n p u n c h
φ 4 .6
H o m e -s id e o p tio n p u n c h
S id e s to p p e r p in
• Set the tilt pins to the surface of the punch so
φ 4 .9
φ 4 .8
φ 4 .7
that the end of the pin with the required outer diameter is facing upward.
S h a p e o f tilt p in s
• Be careful not to use an incorrectly sized tilt pin as the diameters vary depending on the shape of the tilt pin, as shown in the figure on the left. • Use of a tilt pin allows you to shift the punch position in increments of 50 µm.
B-104
PT-R4300 SERVICE MANUAL
B.Installation Punch
5) Restore the option punch to its original position. E n s u re th a t th e p u n c h e d g e to u c h e s th e tilt p in s .
T e m p la te
T ilt p in
When restoring the punch, always ensure that the punch edge touches the tilt pins. 6) Turn ON the power to the PT-R4300 and make punch holes on the plate. Then check the plate deviation following step 3) above.
PT-R4300 SERVICE MANUAL
B-105
B.Installation
6.Relocation This section describes the procedure for relocating the PT-R4000II/PT-R4300 and the relevant operational precautions. 1) Prior to removing the power cable • Move the recording head using the Service/Maintenance Menu screen so that the recording head fixing bracket can be attached. Enter the Service/Maintenance Menu screen. → Enter the Recording unit test screen. → Enter the RH positioning screen. → Move the recording head by 365 mm. (The point where the recording head fixing bracket is attached.) • Ensure that the transfer path is in a horizontal position. (If not, the transfer path fixing bracket cannot be attached.) • Confirm that there is no plate loaded on the recording drum and then confirm that the trailing edge clamps are located at the clamp driver section. 2) Turn OFF the power to the PT-R4300 and remove the power cable, signal cable, blower power cable, blower signal cable, and blower hose. 3) Cleaning Remove the external cover and clean the inside of the machine. • Feed guides (front and rear of the nip roller) • Nip roller, discharge roller • Discharge guide • Punch sections (If the punches have been used for a long time, some aluminum particles will be left around them.) • Surface of the recording drum • Recording head (cover top and objective lens) 4) Attaching fixing brackets Attach the fixing brackets according to the following procedure. 1.
Squeeze roller fixing brackets (HOME side) Cleaning roller fixing brackets
Attach the fixing brackets to the squeeze roller and the cleaning roller.
• The fixing brackets for the squeeze roller and the cleaning roller should be located symmetrically. • Each fixing bracket for the squeeze roller is secured with a nut. Be careful not to drop the nut.
B-106
• Ensure that the fixing brackets for the squeeze roller properly touch the squeeze roller shaft.
PT-R4300 SERVICE MANUAL
B.Installation
Make sure that the end of each fixing bracket’s screw touches the bearing section of the cleaning roller. Squeeze roller fixing brackets Spring washer and thick washer (for M4) Nut (for M4) Cleaning roller fixing brackets M4 x 10 cap bolt Spring washer and thick washer (for M4) 2.
Attach the fixing brackets to the transfer path.
The fixing brackets should be located symmetrically. Transfer path fixing brackets
M4 x 10 cap bolt Spring washer and thick washer (for M4) M5 x 12 cap bolt Spring washer and thick washer (for M5) M6 x 15 cap bolt
Squeeze sideplate fixing brackets
Spring washer and thick washer (for M6) 3.
Attach the fixing brackets to the clamp arm and the squeeze sideplate.
• The fixing brackets should be located symmetrically.
Clamp arm fixing brackets
• Note that if a longer screw is mistakenly used for securing the fixing brackets for the squeeze sideplate, it will contact the clamp driver frame. • Firmly secure the clamp arm. Clamp arm fixing brackets M5 x 12 cap bolt Spring washer and thick washer (for M5) M6 x 15 cap bolt Spring washer and thick washer (for M6) Squeeze sideplate fixing brackets M5 x 8 cap bolt Spring washer and thick washer (for M5)
PT-R4300 SERVICE MANUAL
B-107
B.Installation 4.
Attach the fixing brackets to the engine base.
Be sure to secure the fixing screws in the order shown in the figure below. If you mistakenly secure the screws on the frame side first, the engine base may move during transportation of the machine, which could result in misregistration and front sensor error.
Home side on the front side
Away side on the front side
Center of the rear side
M10 x 25 cap bolt Spring washer and thick washer (for M10) a. First secure the four screws by hand. b. Gradually tighten the four screws using a hexagonal wrench. (Tighten the screws in 60 degree increments.) c. Finally, tighten the screws on the engine base side and then tighten those on the frame side. While tightening the screws, check the contact between the engine base and the fixing bracket. 1
2
E n g in e b a se s id e
E n g in e b a se fixin g b ra c ke t
3 G ra d u a lly tigh te n e a ch s cre w in 6 0 d e g re e in c re m e n ts . (4 p la c e s)
4
F in a lly , s e c u re th e s c re w s in n u m e ric a l o rd e r (fro m 1 to 4 ).
F ra m e sid e
Recording head fixing brackets
5.
Attach the fixing screws for the recording head. The fixing brackets are attached to the recording head base and the electrical system section.
Left side
Right side
• If the fixing bracket positions have shifted laterally, adjust them by turning the knob for the lateral feed motor. • Do not touch the ball screw or rail. (This can cause rust.)
Electrical system sec- For PT- R4300 (s/n: 7, 9 onward) only tion fixing brackets B-108
Reference) Rust preventive lubricant for the rail ThreeBond 1804 PT-R4300 SERVICE MANUAL
Upper side
B.Installation Recording head fixing brackets M6 x 15 cap bolt Spring washer and thick washer (for M6) Electrical system section fixing brackets M5 x 12 cap bolt Spring washer and thick washer (for M5) Ball screw fixing bracket
6.
Attaching the fixing bracket to the ball screw M4 x 10 cap bolt Spring washer and thick washer (for M4)
7.
Attaching the fixing bracket to the blower M10 x 25 cap bolt Spring washer and thick washer (for M10) M6 x 15 cap bolt Spring washer and thick washer (for M6)
Blower fixing bracket Cushioning material for nip roller
8.
Attaching the cushioning materials Open the door of the PT-R4300 and remove the discharge tray. Attach each piece of cushioning material with tape to the positions indicated in the figure.
Left side
Right side
Cushioning material for discharge tray
Next, replace the discharge tray, attach cushioning materials for the discharge guide with tape, and then tape the fixing screws for the discharge guide. Fixing screws
Left side
Right side Discharge tray
PT-R4300 SERVICE MANUAL
B-109
B.Installation Iinterleaf
9.
Protecting the discharge roller Cover the discharge roller of the transfer path with interleaf or other material.
If you do not cover the discharge roller, it may press tightly against the lower roller and an abnormal sound may be heard when a plate is disFilter
charged. 10. Attaching the filter protection tape Tape the filter onto the left side cover of the PTR4300.
Tape
11. Packing the punch debris receptacle Punch debris receptacle
Remove the punch debris receptacle from the rear cover and pack it.
12. Attaching the hoist attachments Attach the hoist attachments and the connecting beam to the lower section of the machine.
Hoist attachments connecting beam
13. Others Protect the operation panel, connector connecting sections, and other parts with vinyl bags.
B-110
PT-R4300 SERVICE MANUAL
B.Installation
7.Installation check sheet Installation data: Person in charge: Mfg. No.: PT-R4000/PT-R4000II/PT-R4300 (s/n:
)
Firmware: Ver. Customer name: Customer address: Option: SA-L4000/MA-L4000/SA-L4300/MA-L4300/AT-T4000/Others ( Media type and plate size to use: Optional punch: Work descriptions Check items Minimum delivery Width: 1760 mm or more, path dimensions Depth: 1150 mm or more, Height: 1185 mm or more Floor load capacity 3920N/m2 (400kgf/m2) Power supply Single-phase 200 V to 240 V +6% -10%, 15 A Single-phase 200 V to 240 V +6% -10%, 20 A Components Check the items on the packing list. Installation of main unit Removal of the Transport fixing bracket: 17 pcs., transport fixing cushioning material: 5 pcs. brackets Level adjustment Blower connection Power connection to main unit Energization Version check Main unit, panel, recording head Initial settings Plate type Plate Printing machine information Exposure conditions Operation checks Lowest position of the transfer path
mm (Margin
)
mm)
Remarks
Check
Main unit only (common to the PT-R4000 (II) and PT-R4300) SA-L/MA-L included
Ensure that the distance between the transfer path and the stopper is within 0.5 mm. Plate loading position onto the drum Ensure that the largest size plate comes into contact with the drum around the area below the leading edge clamp position. Positional relationship between the Ensure that the Away side of the plate is inclined plate and the registration pins while 0.5 to 1.0 mm with respect to the Home side of the the plate is being transferred. plate. (Up to 420) Plate side alignment Ensure that the centering unit bearing is in touch with the plate. Left/right position of the plate with Ensure that the center of the registration pins aligns respect to the registration pins of the with the center of the plate punches or are slightly recording drum shifted to the right (within 0.5 mm). Timing when the nip roller is Ensure that, during plate winding, the plate momenreleased tarily stops approximately 3 mm before reaching the registration pins. Plate winding condition Ensure that the plate is in touch with the registration pins. Operation of the leading edge detection sensors Front sensor offset value Displacement sensor offset value
PT-R4300 SERVICE MANUAL
B-111
B.Installation Work descriptions Check items Operation checks Leading edge clamp grip margin Trailing edge clamp grip margin Teaching of plate lengths in the Y direction Laser calibration Registration punch positions Processor setting Mitsubishi: 30 °C, 20 S; Fuji: 30 °C, checks 12 S; KPG: 30 °C, 25 S Exposure adjust- Focus, zoom, light intensity ment Exposure checks Exposure of the line and space pattern on the entire plate Any scratches on unexposed plates Exposure of tint images Exposure of the grid pattern
Installation of the punch system for printing machine RIP connection Exposure checks from the RIP
B-112
Remarks 13.2 mm (for the standard 15 mm type) 7 mm Ensure that an error occurs when the plate length is ± 2.5 mm of the specified length.
Check
Modify the Punch adjust value, if necessary.
Checking for the plate looseness (all sizes)
Checking positive plates by exposing 85% (0%) tint and negative plates 100% tint. Checking for tilt of the exposed grid pattern and confirmation of correct exposure size and plate registration
Checking the margins and left/right positions
Effective image area Grip margins and left/right exposure positions Screen gradation Checking the resolution (dpi) and screen ruling that are used by the user.
PT-R4300 SERVICE MANUAL
C. Replacement & Adjustment
C.Replacement & Adjustment
1. Main belt replacement 1) Confirm that the power to the PT-R4300 has been turned OFF, and then remove the right side cover.
Motor plate
2) Loosen the motor plate screw. Next mortor plate move to up.
3) Remove the encoder fix plate. (Not need remove encorder) Replacement main belt.
• Do not need oil for belt. • When replacement belt,cut the tie band(down side). Encoder fix plate
4) The appropriate belt tension for the PT-R4000/ 4000II is 6 to 20 kgf. Adjust the belt tension until it is within this range using the belt tension jig. First remove the screw that secures the encoder cable and then attach the belt tension jig as shown in the photo on the left. Next, temporarily secure the motor plate using the motor’s own weight. Once the jig bolt has come into contact with the motor plate surface, rotate the hexagonal bolt a half turn
Belt tension jig
and secure the motor plate screw. The belt tension has now been adjusted appropriately. If the belt vibrates or the output image appears improperly, further rotate the hexagonal bolt approximately one-sixth of a turn to increase the tension.
Belt tension should not be excessively tightened or loosened. Tension adjusting bolt PT-R4300 SERVICE MANUAL
C-1
C.Replacement & Adjustment 5) Fix the encoder fix plate.And remove the belt tension jig. Next fix the encoder cable,turn ON the power to the PT-R4300.
6) Enter the Service/Maintenance Menu screen to ad-
0101
just the drum home position.
P T- R 4 X X X
Simultaneously press the two areas marked with circles on the screen shown on the left.
Please press [START]
START
’01.05.01 V1.00
→ Enter the Service/Maintenance Menu screen. → Enter the Drum Test screen and press Zero Return. (The pulse at the encoder home position will be checked.) → Rotate the drum by hand until it reaches the position where lock pins can be inserted. (The drum can be rotated in the either direction.) → Execute the Actuator test command to insert the lock pin into the drum on both the Home and Away sides.
Position where the lock pin can be inserted into the drum
→ Enter the Drum base position screen from the Input parameter screen then read and save the drum home position. (Save the setting.) → It is also possible to initialize the main unit. 7) Load a plate onto the drum and perform exposure of a test pattern to check that the image is output with no problem. A jig for the PT-R4300 is currently being developed. (As of May 7, 2002)
L-shaped wrench (for M6 screws and M4 set screws) Belt tension jig Approximately 1 hour C-2
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment How to adjust the belt tension without using a belt tension jig 1) Push one side of the belt toward the opposite side with your hand and measure the space between the belt positions. 2) After replacing the belt, push one side of the belt toward the opposite side with your hand and adjust the belt tension until the space between the belt positions is equivalent to that of the previous belt. 3) Load a plate onto the drum and perform exposure of a test pattern to check that the image is output with no problem.
PT-R4300 SERVICE MANUAL
C-3
C.Replacement & Adjustment
2. Encoder replacement 1) Confirm that the power to the PT-R4300 has been Encoder
turned OFF, and then remove the right side cover. 2) Remove the encoder cover.
3) Loosen the two M3 set screws which are used to fix the encoder to the drum shaft.The encoder is hollow. A drum shaft goes into the encoder center hole and connects it with the encoder.
4) Remove the encoder fixing screws and replace the encoder with a new one. Also replace the cable tie band with a new one.
Positions for encoder fixing screws
5) Insert the drum shaft into the encoder hole until the plate spring bracket used for the encoder attachment comes into contact with the attachment plate. One of the set screws must be set against the shaft’s D-cut portion. Push the encoder to the parts contact point.
Attachment plate Attachment plate C-4
Encoder PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 6) Fix the set screws while the drum is rotating.Install the encoder so that any distortion of its rear side caused by rotation of the drum is within 50 µm. If the amount of distortion exceeds 50 µm, it will result in deterioration of the image quality.
If the centers cannot be adjusted precisely, set the shaft’s D-cut portion with the other set screw. Set the encoder distortion to within 50 µm with a micro gauge.
7) Re-attach the encoder cover and turn ON the power.
0101
P T- R 4 X X X
8) Enter the Service/Maintenance Menu screen to adjust the drum home position.
Please press [START]
START
’01.05.01 V1.00
Simultaneously press the two areas marked with circles on the screen shown on the left. → Enter the Service/Maintenance Menu screen. → Enter the Drum Test screen and press Zero Return. (The pulse at the encoder home position will be checked.)
It is also possible to initialize the main unit. → Rotate the drum by hand until it reaches the position where lock pins can be inserted. (The drum can be rotated in the either direction.) → Execute the Actuator test command to insert Position where the lock pin can be inserted into the drum
the lock pin into the drum on both the Home and Away sides. → Enter the Drum base position screen from the Input parameter screen then read and save the drum home position. → Turn OFF and ON the power to the PTR4300 to initialize the machine.
PT-R4300 SERVICE MANUAL
C-5
C.Replacement & Adjustment 9) Turn OFF the power to the PT-R4300 and re-attach the right side cover. L-shaped wrench (for M4 screws and M3 set screws) Ball driver (for M3 screws) Magnet stand Micro gauge (minimum scale: 10 µm) Tie band (small size: 2 pcs.) Approximately 1 hour
C-6
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
3. Adjusting the automatic balancer weight detection sensors (Perform this procedure when the operations such as weight replacement, sensor replacement/ adjustment, etc. are required.) 3505
1) Confirm that the power to the PT-R4300 has been
RH zero return
turned OFF, and then remove the right side cover, front cover, front left cover and rear cover.
RH positioning Focus zero return
2) Turn ON the power to the PT-R4300. → Enter the Service/Maintenance Menu screen.
Focus positioning Zoom zero return ESC
OK
NEXT
→ Enter the Recording head test screen. → Enter the RH positioning screen. → Input 350 mm and press OK. (This facilitates observation of the balancer movement.)
Weight
3) Weights will not be positioned against the outer side of the guide groove of the drum immediately after being moved (or attached) by hand (for example after a weight replacement.)The weights are normally pressed against the outer side of the guide groove because they are moved there by centrifugal force. If the weights are not correctly pressed against the outer side of the guide groove, the hole of each weight will be positioned inwards (or downwards) in respect to its correct position and thus, will be misGuide groove Bracket
aligned with the pushpin position. If this occurs, push the weights up toward the outer side by hand. 4) Sensor adjustment → Enter the Service/Maintenance Menu screen. → Enter the Special action 2 screen. → Enter the Balancer test screen. → Specify the printing machine setting number in the Printing No. *> screen and press OK. (Enter the setting number from among 1 to 15 to “*”)
Adjust the brackets for the balancer weight position detection sensors in the front and back directions (as indicated with an arrow in the figure above.)
→ According to the setting selected above, the PTR4300 automatically moves the weights on the Home side first. (After the Home side weights are completely moved, the Away side ones will be moved.) When the weights are moved, check whether or not the tip of the moving pin properly enters the center hole of each weight.
PT-R4300 SERVICE MANUAL
C-7
C.Replacement & Adjustment If it is misaligned, adjust the bracket for the balancer weight position detection sensor in the front and back directions. An error will occur if the weight detection sensors are defectively positioned.
• If the same printing machine setting is repeatedly selected, the weights will move only the first time. Therefore, select a different setting number every time. • The drum rotates clockwise when viewed from its right. 4460
5) Confirmation → Enter the Service/Maintenance Menu screen.
Initialize Balancer test
→ Enter the Special action 2 screen. → Enter the Balancer test screen.
Mail test
→ Specify the printing machine setting number in the Printing No. *> screen and press OK.
Auto loader test Plate pad test ESC
OK
NEXT
(Enter the setting number from among 1 to 15 to “*”) Repeat the selection several times to confirm that the weights are smoothly moving. 6) Turn OFF the power to the PT-R4300 and reattach the removed covers. L-shaped wrench (for M3 screws) Ball driver (for M3 screws) Approximately 30 minutes (for sensor adjustment)
C-8
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
4. Removing the trailing edge clamps 1) Confirm that the power to the PT-R4300 has been turned OFF, and then remove the right side cover and rear cover. 4450
2) Turn ON the power to the PT-R4300 and enter the Service/Maintenance Menu screen.
Initialize Initialize machine status Pick up clamp
→ Enter the Special action screen. → Select Put clamp on drum and press OK. → Mount the trailing edge clamps on the drum.
Check ORG-EZ Put clamp on drum ESC
OK
NEXT
Trailing edge clamp
3) Rotate the drum by hand until the trailing edge clamps faces the rear side, then execute Servo ON. Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (ON) and press OK
It is easier to remove the clamps when they are positioned as shown in the figure above. Hold down here to release the tabs.
4) While holding the center of the trailing edge clamp spring section push the tabs with your fingers to remove an individual trailing edge clamp from the drum.
• Carefully conduct this operation to maintain the flatness of the trailing edge clamps. If any of them are not flat, a plate may detach from the drum during exposure. • Do not wind plates while the trailing edge Spring section
clamps are removed.
None Approximately 10 minutes PT-R4300 SERVICE MANUAL
C-9
C.Replacement & Adjustment
5. Attaching the trailing edge clamps Before attempting to replace the trailing edge clamps, note down the weights which are written on the back side of each trailing edge clamp.
1) Confirm that the power to the PT-R4300 has been turned OFF, and then remove the right side cover and rear cover.
Positioning bolts
2) Turn ON the power to the PT-R4300 and rotate the drum by hand until the positioning bolts on the drum faces the rear side, then execute Servo ON. Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (ON) and press OK.
3) Attach the trailing edge clamps along the respective positioning bolts on the drum. 1. Touch the trailing edge clamps to the positioning bolts. (The spring section of each clamp is on the upper side.) 2. Slide the trailing edge clamps laterally while they are lightly touching the drum and then position them when the tabs come evenly into contact with the clamp rails. In this state, the surfaces of the clamp tabs are horizontal with respect to the clamp surface. • When the clamp is shifted to the right, the right tab appears as if it is being pressed down.
C-10
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 3. Press the upper position (center of the spring section) of each trailing edge clamp to secure it to the drum. Be aware of the following points when attaching the trailing edge clamps. • The trailing edge clamps are marked with H, M or A on their respective back sides. An “H” marked one should be used for the Home side. An “M” marked one should be used for center. An “A” marked one should be used for the Away side.
Completed trailing edge clamps
• Attach the trailing edge clamps so that each spring section is positioned on the upper side and each plate retaining section is positioned on the lower side. Attach the trailing edge clamps while the outer side of the plate retaining section touches the positioning bolts. • Since the PT-R4300 supports wider plate sizes, the grooved plate attachment screws interfere with the trailing edge clamps. This makes the attachment of the trailing edge clamps relatively difficult. Place the spring section onto the area above the screws and secure each clamp. Then, align the clamps with the positioning bolts. 4) Input the total weight of the new trailing edge
4130
CLR
Clamper:
381.2[g]
Balancer:
165.0[g]
ESC
SAVE
7
8
9
4
5
6
1
2
3
0
• ENT
clamps. Enter the Service/Maintenance Menu screen. → Enter the Input parameter screen. → Enter the Set weight screen. → Input the total weight of the three trailing edge clamps into the “***.**” field of “gclamper ***.**”. → After the total weight input is complete, press ENT and SAVE.
Always replace the three clamps at the same time.
PT-R4300 SERVICE MANUAL
C-11
C.Replacement & Adjustment 4450
5) Mount the trailing edge clamps to the drive bar.
Initialize Initialize machine status
Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Pick up clamp and press OK.
Pick up clamp Check ORG-EZ
6) Turn OFF the power to the PT-R4300 and reattach the removed covers.
Put clamp on drum ESC
OK
NEXT
None Approximately 10 minutes
C-12
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
6. Replacement procedure for the trailing edge clamp arm drive motor (M20) When the motor (M20) is operating 1) Turn OFF the power to the PT-R4300 and remove the right side cover and the rear cover. 4450
2) Turn ON the power to the PT-R4300. Enter the Service/Maintenance Menu screen.
Initialize Initialize machine status Pick up clamp
ESC
→ Enter the Special action screen. → Select Put clamp on drum and press OK.
Check ORG-EZ
→ Attach the trailing edge clamps to the drum.
Put clamp on drum
3) Rotate the drum by hand until either the leading or
OK
NEXT
trailing edge clamps are positioned under the clamp arm and then execute Servo ON. Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (ON) and press OK. 4) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Select Trail edge clamp arm “DOWN” and press OK.
Ensure that, at this moment, the clearance between the end of the hook pin and the drum surface is approximately 1 mm. 5) Remove the trailing edge clamp arm drive motor (M20), which is attached to the Home side, together with the gear box (8DG150). 6) After replacing the motor, turn ON the power to the PT-R4300. Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Select and execute Trail edge clamp arm “UP” Motor with gear box
and “DOWN” repeatedly to confirm proper operation.
Sensor adjustment is not necessary at this stage.
PT-R4300 SERVICE MANUAL
C-13
C.Replacement & Adjustment When the motor (M20) is not operating 1) Turn OFF the power to the PT-R4300 and remove the right side cover and the rear cover. 2) Rotate the drum by hand until the leading edge clamps are positioned at the lower side of the drum and then execute Servo ON. Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. Bolt
Cam follower flange
→ Select Servo (ON) and press OK. 3) Insert a bolt into a hole on the cam follower flange on both the Home and Away sides. Remove the trailing edge clamp arm drive motor (M20), which is attached to the Home side, together with the gear box (8DG150).
• Take care during the above removal operation. Removing the drive motor attachment screws detaches the motor gear from the other gear. At this moment, the weight of the clamp arm will cause it to fall onto the drum side. Support the clamp arm by hand until it lowers to the screw position and is settled. • Use an M6 bolt. 4) Replace the motor with a new one. 5) After replacing the motor, turn ON the power to the PT-R4300. Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Select and execute Trail edge clamp arm “UP” and “DOWN” repeatedly to confirm proper operation. Drive motor and Gear box
Sensor adjustment is not necessary at this stage.
C-14
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
7. Adjusting the trailing edge clamp arm origin and end sensors Adjustment of the trailing edge clamp arms is not required when only the sensors are replaced. However, the procedure in this section includes an explanation of sensorrelated operation checks.
4450
1) Confirm that the power to the PT-R4300 has been turned OFF, and then remove the right side cover and rear cover.
2) Turn ON the power to the PT-R4300 and enter the Service/Maintenance Menu screen.
Initialize Initialize machine status
→ Enter the Special action screen. → Select Put clamp on drum and press OK.
Pick up clamp
ESC
Check ORG-EZ
→ Mount the trailing edge clamps on the drum.
Put clamp on drum
3) Rotate the drum by hand until either the leading or
OK
trailing edge clamps are positioned under the clamp arm and then execute Servo ON. Enter the Service/
NEXT
Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (ON) and press OK. 4) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Select Trail edge clamp arm “DOWN” and press OK.
Ensure that, at this moment, the clearance between the end of the hook pin and the drum surface is approximately 1 mm. 5) Together with the gear box (8DG150), remove the clamp arm drive motor (M20) which is attached to the Home side. Drive motor and Gear box
6) Move the sensor bracket to a position where the trail-
Sensor dog
ing edge clamp arm end sensor (PH21) reacts when the clamp arm is positioned at its lower limit point while the motor is detached, and then fix the bracket there.
This adjustment is required only when the sensor bracket fixing screws are loosened, for example, when only the sensor is replaced. In addition, this adjustment is not required when Trailing edge clamp arm end sensor (PH21) PT-R4300 SERVICE MANUAL
only the motor or sensor is replaced. C-15
C.Replacement & Adjustment Point: The positions of origin and end sensors for the trailing edge clamp arms are appropriate when each cam follower is horizontally set, each sensor detects a sensor dog, and there is clearance when the area circled in the figure on the left is pressed on both the left and right sides.
Press this area by hand.
Cam follower
7) Once the adjustment has been completed, reattach the motor. Trailing edge clamp arm origin sensor (PH20) 8) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Select Initialize and press OK to initialize the machine. Set Traid edge clamp arm to Up. Adjust the position of the sensor bracket so that the clamp arm unit stops at the upper limit point (visually confirmed).
This adjustment is required only when the sensor bracket fixing screws are loosened, for example, when only the sensor is replaced. In addition, this adjustment is not required when only the motor or sensor is replaced. 9) Attach the clamps to the clamp arm in accordance with the instructions in “Removing the trailing edge clamps” and “Attaching the trailing edge clamps”. Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Repeatedly set Trail edge clamp arm to Up and Down to confirm the smooth operation of the clamp arms. 10) Turn OFF the power to the PT-R4300 and reattach the removed covers.
C-16
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment Reference
Cam follower
Clamp arm Drum
Clamp arm at its lowest position
Clamp arm at its center position
Clamp arm at its highest position
Ineffective
Screwdriver (cross-slot type) Approximately 30 minutes
PT-R4300 SERVICE MANUAL
C-17
C.Replacement & Adjustment
8. Adjusting the leading edge clamp open/close sensors The type of compression springs used for the leading edge clamps have been changed. This is due to an engineering change to facilitate adjustment of the opening width of the leading edge clamps and to stabilize the open/close operation. (For details, refer to technical information No. 0009. PT-R4300s with serial No.: 0071 and onward.) Note that different types of compression spring cannot be used together. 1) Confirm that the power to the PT-R4300 has been turned OFF, and then remove the right side cover, rear cover and front cover. 3202
M20:Squeeze roller
Up
Down
M20:Tail edge clamp arm
Up
Down
M24:Tail edge clamp hook
Hold
Rele
M30:Leading edge clamp
Up
Down
2) Turn ON the power to the PT-R4300 and rotate the drum by hand until the leading edge clamps are positioned at the lower side of the drum. Then, follow the procedure below. Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (ON) and press OK.
ESC
OK
3) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Leading edge clamp to Down. Then, move the attachment position of the brackets for the leading edge clamp open sensors (PH31H, PH31A) in the front/back directions so that the clearance between the leading edge clamp release bar and the drum can be adjusted. Adjustment values PT-R4000 (up to serial number 70): 5 mm PT-R4000 (serial numbers 71 to 420): 4.5 mm PT-R4000II (serial number 421 and onward): Point: Use a 5 mm diameter hexagonal wrench to check the 5 mm clearance.
4.5 mm PT-R4300 (serial number 1 and onward): 4.5 mm 4) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Leading edge clamp to up. → Enter the Drum test screen. → Select Leading edge clamp and press OK. Rotate the drum to the plate winding start position.
For 4.5 mm: Adjust using a 4 mm hexagonal wrench and a 15 cm scale. C-18
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 5) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Lock pin (Home) to In. → Set Lock pin (Away) to In. Perform the drum positioning. 6) Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (OFF) and press OK. → Release the servo function. View the machine from the front or the side to confirm that the leading edge clamps open by approximately 4 mm.
Leading edge clamp
And also make sure that the gear of the motor should not reverse when its movement stopped.
The width of the opening for the leading edge clamp should be approximately 4 mm. Bracket for leading edge clamp open/ close end sensor (PH31H)
7) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Leading edge clamp to Down. → Set Leading edge clamp to Up. Repeat this process to confirm smooth operation. 8) Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Initialize and press OK to initialize the machine. 9) Turn OFF the power to the PT-R4300 and reattach the removed covers.
L-shaped wrench (for M5 and M4 screws) Approximately 30 minutes PT-R4300 SERVICE MANUAL
C-19
C.Replacement & Adjustment
9. Replacement and adjustment procedure for the plate side edge detection sensors for side alignment (PH61H, PH61A) After replacing the plate side edge detection sensors, the following sensor offset values need to be adjusted.Use the 510 x 400 x 0.15 plate. (If it is not available, use the thinnest plate from among the customer’s plates.) 1. Coarse adjustment 1) Confirm that the power to the PT-R4300 has been turned OFF, and then remove the upper rear cover and rear cover.
Graduated scale
2) Turn ON the power to the PT-R4300 to initialize the machine.
Plate
3) Open the operation door and set a plate on the transfer path.The plate must be aligned with the graduated scale on the transfer path. 4) Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Centering test → Select “plate size” and OK Set the plate center within 10 mm of the path center.
If an error occurs, perform the operation in “Countermeasure for errors” described later and then go back to step 3) above.When the test has been successfully completed with no error, press
4451
“ESC” key . The first parameter in “Punch Adjust” has to be
Front sensor offset Centering test Adjust displacement sensor
will be detemined without error. And then the middle value betweeen them has to
NVRAM backup NVRAM restore
ESC
OK
determined by changing this value every 0.5 mm, and then the maximum and the minimum value
be set. NEXT
5) Shift the plate 10 mm to the Home side (Away side) and execute the Centering test command to confirm that no error occurs.
The cam follower pushing against one side of the plate at this moment will not affect the operation.
C-20
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 2. Fine adjustment 1) Move the plate 10 mm toward the Away side and enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Centering test and press OK. At this time, be sure that the distance between the plate center and the path center does not exceed 10 mm. Move the plate to the Away side.
2) If an error occurs, perform the operation in “Countermeasure for errors” described later and then go back to step 1) above. When no error occurs, go on to step 3). 3) When the plate stopper (Home side cam follower) has pushed the plate to the farthest point on the Away side during the centering operation, confirm with your hands and eyes that the plate is properly centered. Then check the following points. • When the plate stopper has pushed the plate too far: Enter the Service/Maintenance Menu screen.
Confirm here.
→ Enter the Input parameter screen. → Reduce the second parameter value for Punch
3860
CLR
Punch adjust
7
8
9
4
5
6
1
2
3
0
•
0.000 [mm] 0.000 [mm] 0.000 [mm]
ESC
SAVE
ENT
Change the value here.
adjust, execute the Centering test command again to cancel the test mode and then go back to step 1) above. • When the plate stopper does not reach the plate: Increase the second parameter value for Punch adjust, execute the Centering test command again to cancel the test mode and then go back to step 1) above. • When the plate stopper pushes the plate correctly: (Although you will feel some resistance when attempting to move the plate by hand, the plate can be moved.) Execute the Centering test command again to cancel the test mode and then go on to step 4) below.
PT-R4300 SERVICE MANUAL
C-21
C.Replacement & Adjustment 4) Move the plate 10 mm toward the Home side and enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Execute the Centering test command. At this moment, be sure that the distance between the plate center and the path center does not exceed 10 mm. Move the plate to the Home side.
5) If an error occurs, perform the operation in “Countermeasure for errors” described later and then go back to step 4) above.When no error occurs, go on to step 6). 6) When the plate stopper (Away side cam follower) has pushed the plate to the farthest point on the Away side during the centering operation, confirm with your eyes that the plate is properly centered. Then check the following points. • When the plate stopper has pushed the plate too far: Enter the Service/Maintenance Menu screen. → Enter the Input parameter screen.
Confirm here. 3860
CLR
Punch adjust
7
8
9
4
5
6
1
2
3
0.000 [mm] 0.000 [mm] 0.000 [mm]
0 ESC
SAVE
• ENT
Change the value here.
→ Reduce the third parameter value for Punch adjust, execute the Centering test command again to cancel the test mode and then go back to step 4) above. • When the plate stopper does not reach the plate: Increase the third parameter value for Punch adjust, execute the Centering test command again to cancel the test mode and then go back to step 4) above. • When the plate stopper pushes the plate correctly: (Although you will feel some resistance when attempting to move the plate by hand, the plate can be moved.) Execute the Centering test command again to cancel the test mode and then go on to step 7) below.
C-22
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 7) Align the plate center and the path center and execute the Centering test command again.Check the plate centering condition, when the plate stopper pushes the plate farthest at this moment.When the plate has been properly pressed (Although you will feel some resistance when attempting to move the plate by hand, the plate can be moved.), execute the Centering test command again to cancel the test mode and then complete the adjustment operation.If the plate has been pressed too far or insufficiently, go back to step 2. – 1) above. And the plate size must be back to the catalogue size in the end. 8) After completing the adjustment, check the amount that each plate stopper pushes all of the different plate sizes. Smaller plates are likely to be pushed excessively. 9) Turn OFF the power to the PT-R4300 and reattach the removed covers. 3860
CLR
Punch adjust
7
8
9
4
5
6
1
2
3
0
•
0.000 [mm] 0.000 [mm] 0.000 [mm]
ESC
SAVE
ENT
[Countermeasure for errors] • When the “The size check program of the centering function detects that the measured plate size is shorter than expected one” error message is displayed, increase the 1st parameter value in the Punch adjust of the Input parameter in the service/ maintenance mode. • When the “The size check program of the centering function detects that the measured plate size is longer than expected one” error message is displayed, reduce the 1st parameter value in the Punch adjust of the Input parameter in the service/maintenance mode. • When the “When alignment is performed, plate set position is out of range” error message is displayed, set the plate so that the plate center will be positioned within 10 mm of the path center.
None Approximately 30 minutes PT-R4300 SERVICE MANUAL
C-23
C.Replacement & Adjustment Centering sequence (for PT-R4300) Start
Plate thickness is 0.24 mm or less?
Yes
No Transfer motor: 50 mm/ sec.
Both PH61H and PH61A are OFF?
Transfer motor: intermittent drive
Ex1c9
No
Yes Plate side alignment drive motor: M61 Forward rotation at 20 mm/sec.
[Moving distance] Home side: (830 - Plate's X size) / 2 + 27.65 + offset value Away side: (830 - Plate's X size) / 2 + 22.5 + offset value Offset value: First parameter displayed in the screen.
Interruption of PH61H ON status → Remaining distance is stored. (restPH)
Interruption of PH61A ON status → Remaining distance is stored. (restPA)
M61 stops due to any of the following conditions: Remaining distance is "0". Both PH61H and PH61A are ON. Remaining distance > (15 + 1.5)
Remaining distance > 2 mm
Yes Ex156
No PH61H or PH61A is OFF?
Yes
Ex157
No restPH > (15 + 1.5) mm or restPA > (15 + 1.5) mm
Yes
Ex1c9
No restPH > restPA
[Home side offset value] Second parameter displayed in the screen. [Away side offset value] Third parameter displayed in the screen.
Yes
No D = restPA - restPH
D > 1.5 mm + Away side offset value No
Plate side alignment drive motor: M61 Forward rotation at 1.25 mm/sec.
D = restPH - restPA
Yes
D > 1.5 mm + Home side offset value D = 1.5 mm + Away side offset value
No
Yes
D = 1.5 mm + Home side offset value
Further movement of the plate stoppers = 1.5 + (Home side offset value + Away side offset value - D) / 2
Waiting for 0.5 sec.
Plate side alignment drive motor: M61 Reverse rotation by 3 mm at 5.0 mm/sec.
Waiting for specified period
Plate thickness is 0.15 mm or less? No
Waiting time [sec.] = 5 - {(830 - plate's X size) / 2} / 20 / 2
Yes Transfer motor: Continuous feeding at 50 mm/sec.
Plate side alignment drive motor: M61 Forward rotation by 3 mm at 5.0 mm/sec.
Waiting for 2 sec.
Transfer motor stops.
End
C-24
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment Centering sequence (for PT-R4000/PT-R4000II) Start
Plate thickness is 0.24 mm or less?
Yes
No Transfer motor: 50 mm/ sec.
Both of PH61H and PH61A are OFF?
Transfer motor: intermittent drive
Ex1c9
No
Yes Plate side alignment drive motor: M61 Forward rotation at 20 mm/sec.
[Moving distance] Home side: (830 - Plate's X size) / 2 + 27.65 + offset value Away side: (830 - Plate's X size) / 2 + 22.5 + offset value Offset value: First parameter displayed in the screen.
Interruption of PH61H ON status → Remaining distance is stored. (restPH)
Interruption of PH61A ON status → Remaining distance is stored. (restPA)
M61 stops due to either of the following conditions: Remaining distance is "0". Both PH61H and PH61A are ON.
Remaining distance > 2 mm
Yes Ex156
No PH61H or PH61A is OFF?
Yes
Ex157
No restPH > (15 + 1.5) mm or restPA > (15 + 1.5) mm
Yes
Ex1c9
No restPH > restPA
[Home side offset value] Second parameter displayed in the screen. [Away side offset value] Third parameter displayed in the screen.
Yes
No D = restPA - restPH
D > 1.5 mm + Away side offset value No
Plate side alignment drive motor: M61 Forward rotation at 1.25 mm/sec.
D = restPH - restPA
Yes
D > 1.5 mm + Home side offset value D = 1.5 mm + Away side offset value
No
Yes
D = 1.5 mm + Home side offset value
Further movement of the plate stoppers = 1.5 + (Home side offset value + Away side offset value - D) / 2
Waiting for 1 sec.
Plate side alignment drive motor: M61 Reverse rotation by 3 mm at 5.0 mm/sec.
Waiting for specified period
Plate thickness is 0.15 mm or less? No
Waiting time [sec.] = 5 - {(830 - plate's X size) / 2} / 20
Yes Transfer motor: Continuous feeding at 50 mm/sec.
Plate side alignment drive motor: M61 Forward rotation by 3 mm at 5.0 mm/sec.
Waiting for 5 sec.
Transfer motor stops.
End
PT-R4300 SERVICE MANUAL
C-25
C.Replacement & Adjustment
10. Adjusting the trailing edge clamp hook sensor 1) Remove the right side cover, front cover and rear cover. 4450
2) Turn ON the power to the PT-R4300.
Initialize Initialize machine status
→ Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Put clamp on drum and press OK to mount the trailing edge clamps on the drum.
Pick up clamp Check ORG-EZ Put clamp on drum ESC
OK
NEXT
3) Rotate the drum by hand until the leading edge clamps are positioned at the lower side of the drum and then fix the drum. → Enter the Service/Maintenance Menu screen. → Enter the Drum screen. → Select Servo (ON) and press OK.
Do not remove this sensor unit (on the Away side). Only remove the sensor unit on the left side.
4) Remove the cleaning roller. Next, remove the screws that attach the hook lever switch sensor unit (on the Home side only) to slightly move up the sensor unit.
While moving the clamp hook, be careful not to catch the sensor cable as well.
Sensors (PH24-2, PH24-1)
5) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Trail edge clamp hook to Rele and adjust the tab positions for the trailing edge clamp hook sensors (PH24-1, PH24-2.) Each hook lever that moves up and down is positioned at its lower limit, where a bearing cam lightly mounts the top
Tab C-26
surface of a slide-shaped part. Tab: A metal plate to attach the clamp hook sensor PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment The drive bar has been removed in the photo above to make it easier to observe the unit. Do not remove it, however, during actual operation. Otherwise the accurate adjustment of the drum and the drive bar will be lost.
PH24-1 PH24-2 on on
Rele Hold (one pressing) Hold (two pressings)
off on
off off
on→The light passage to the sensor is not obstructed. 6) Enter the Service/Maintenance Menu screen.
3202
M20:Squeeze roller
Up
Down
M20:Tail edge clamp arm
Up
Down
M24:Tail edge clamp hook
Hold
Rele
M30:Leading edge clamp
Up
Down
ESC
OK
→ Enter the Actuator test screen. → Repeatedly set Trail edge clamp to Rele and Hold to confirm the smooth operation of the clamp hook. 7) Re-attach the sensor unit which was removed in step 4) above. Re-attach the cleaning roller.
Activate the clamp hook to confirm that it does not catch with the sensor cable. 8) Attach the trailing edge clamps to the drive bar following the procedures described in “Removing the trailing edge clamps” and “Attaching the trailing edge clamps” sections. 9) Turn OFF the power to the PT-R4300 and reattach the removed covers.
The sensor bracket has been attached to the Home side when the machine is delivered.
L-shaped wrench (for M4 screws) Nipper Interlock release jig Approximately 1 hour PT-R4300 SERVICE MANUAL
C-27
C.Replacement & Adjustment Clamp mechanism (Reference) mechanism(Reference)
Sensors (PH24-2, PH24-1) Hook lever
Jig
C-28
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
11. Adjusting the hook lever switch Hook lever switches are only installed in PT-R4000s with serial numbers 1 to 35. Therefore, this adjustment is only required for these machines. 1) Remove the right side cover, front cover and rear cover. 4450
2) Turn ON the power to the PT-R4300.
Initialize
→ Enter the Service/Maintenance Menu screen. → Enter the Special action screen.
Initialize machine status
→ Select Put clamp on drum and press OK to mount the trailing edge clamps on the drum.
Pick up clamp Check ORG-EZ Put clamp on drum ESC
NEXT
OK
3) Rotate the drum by hand until the leading edge clamps are positioned at the lower side of the drum and then fix the drum. Enter the Service/Maintenance Menu screen. → Enter the Drum screen. → Select Servo (ON) and press OK.
3100 11 PH10H
6
PH11A2
11
PH27-1
16
PH30H
2
PH10A
7
PH20
12
PH27-2
17
PH30A
3
PH11H1
8
PH21
13
PH27-3
18
PH31H
4
PH11H2
9
PH24-1
14
PH29H
19
PH31A
5
PH11A1
10
PH24-2
15
PH29A
20
LS28
4) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Trail edge clamp to Rele twice consecutively to confirm that the hook lever switches (LS28) turn ON.
ESC
OK
NEXT
• Check that all hook levers have returned. • Enter the Service/Maintenance Menu screen. → Enter the Sensor screen to confirm that the sensors are actually ON. 5) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Trail edge clamp hook to Hold and confirm that the hook lever switches (LS28) turn OFF. In addition, set Trail edge clamp hook to Rele> and confirm that the hook lever switches (LS28) are still OFF.
PT-R4300 SERVICE MANUAL
C-29
C.Replacement & Adjustment Brackets for the hook lever switches
6) If the confirmations described in steps 4) and 5) above were not successfully performed, adjust the attachment positions of brackets for the hook lever switches (LS28-1 to LS28-6) in the vertical direction until the hook lever switches work as described in steps 4) and 5). Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → When Trail edge clamp is set to Rele twice continuously, the hook lever actuators monitored by the hook lever switches (LS28-1 to LS28-6) must be within 0.5 mm to their respective stroke end points (0.5 mm before the red notch on each sensor micro switch is fully pressed.) 7) Repeat steps 4) and 5) to confirm that the hook lever switches correctly turn ON and OFF. 8) Attach the trailing edge clamps to the drive bar following the procedures described in “Removing the trailing edge clamps” and “Attaching the trailing edge clamps” sections. 9) Turn OFF the power to the PT-R4300 and reattach the removed covers.
L-shaped wrench (for M3 screws) Approximately 1 hour C-30
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
12. Sensor for detecting an interleaf on the back of the plate (PH51) The following sensitivity adjustment is required after the sensor for detecting an interleaf on the back of the plate is replaced. Detection hole
1) Turn ON the power to the PT-R4300 to initialize the machine and open the operation door. 2) Place a plate over the detection hole of the transfer path. 3) Press the SET button for the sensor amplifier unit.At this moment, the tuning indicator for the sensor amplifier unit will be ON (yellow LED).
Transfer path
4) Remove the plate placed over the detection hole and place an interleaf over the detection hole. 5) Press the SET button for the sensor amplifier unit.At this moment, the tuning indicator for the sensor amplifier unit will be ON (yellow LED). 6) Confirm that the amplifier operation indicator (red LED) is ON when an interleaf that has been layered Plate
with a plate is placed over the detection hole. The indicator should be OFF when a plate alone is placed over the detection hole or the detection hole is left uncovered.
LON
SET Lamp
OFF.D ON.D OFF DON
operation indicator
Lock
7) Turn OFF the power.
Interleaf Sensor amplifier unit
SET button
Sensor amplifier
None Approximately 20 minutes PT-R4300 SERVICE MANUAL
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C.Replacement & Adjustment
13. Replacement and adjustment procedure for the plate top side detection sensors (PH29H, PH29A) The following adjustment is required after the plate top side detection sensors (PH29H, PH29A) are replaced.Be sure to turn OFF the power to the PT-R4300 during the sensor replacement. When using the PT-R4000 (Ver. 3.XX or lower) 1) Turn OFF the power to the PT-R unit and remove the front cover and the rear cover. Then, replace the sensors. Drum surface 22mm PH29H
26mm
26mm A PH29
2) Turn ON the power to the PT-R4300 to initialize the 22mm
machine. 3) Fix the replaced sensors at the angle shown in the figure on the left. 4) Rotate the drum until it reaches the leading edge clamp open/close position, where lock pins can be inserted into the drum. → Enter the Actuator test screen. → Set Lock pin (Home, Away) to IN. 5) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set the Leading edge clamp to down and mount a test plate (jig) from the front side.
Prepare a test plate as a jig. (With Register Punch) One of the user’s plates can be used.
less than 70mm
Trimmer
6) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Leading edge clamp to up to grip the plate. → Set Lock pin (Home, Away) to OUT. 7) Enter the Service/Maintenance Menu screen. → Enter the Drum test screen. → Select Servo (OFF) and press OK.
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PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 8) Enter the Service/Maintenance Menu screen. → Enter the Sensor test screen. → Light up the PH29H and PH29A sensor indicators. 9) Position the drum by hand so that the sensor rays in area around the top side of the plate seen through the (70-80%)
detection hole. 10) Enter the Service/Maintenance Menu screen.
Adjust the trimmer so that the sensor turns ON when approximately 70 to 80% of this area of the plate is exposed by the sensor beam.
→ Enter the Drum test screen. → Select Front check and press OK. and confirm sensor doesn’t light on. Confirm that the sensor light must be off. If not, enter the service maintenance mode, → Input parameter view
Plate
→ Drum position view → Adjust the value of the Front sensor. (Decrease value can move to clock side) 11) Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Sensor offset. → Select Plate type and press OK. 12) Confirm the correct sensor operations by the manual Check that the Home and Away side sensors are simultaneously ON in the area around the top side of the plate.
loading of a plate.
Be sure to confirm the sensor operations using all 4451
the plates that the customer will use. And Adjust the offset if the thickness is different
Front sensor offset Centering test Adjust displacement sensor
13) Turn OFF the power to the PT-R4300 and reattach
NVRAM backup
the removed covers.
NVRAM restore
ESC
OK
just in case even though the same type of plate.
NEXT
Screwdrivers (small flat-bladed type) L-shaped wrench (for M3 screws) Tie band Nipper Approximately 30 minutes PT-R4300 SERVICE MANUAL
C-33
C.Replacement & Adjustment When using the PT-R4000 (Ver. 4.XX or later), PT-R4000II, or PT-R4300: In Ver. 4.00, modifications have been made to the Front check sequence in order to enhance the operation speed. These modifications also allow the effective detection area for Front check to be specified by the operator. • Before modification 1. The drum was rotated toward the position for front check. 2. The drum was rotated at low speed and the positions at which the home and away front sensors turned ON were detected according to the programmed setting. • After modification 1. The positions at which the home and away front sensors turn ON are detected in the effective detection area during drum rotation according to the operator specified setting. #Precaution Due to the sequence modification, upgrading the firmware to Ver. 4.00 may cause a front sensor error and thus prevent plates from winding around the drum. To avoid this, perform the following checks and adjustments before upgrading. [Check and adjustment procedure] 1. Check the front check position that is currently set. After winding a plate around the drum, select “Drum test” and then “Front check”. Check that either the home or away front sensor is ON. The adjustment is not required when either sensor is ON. 3300
Zero Return
Fast
Slow
Leading Clamp
Squeeze
Front check
Tail clamp
Edge sense
Servo (ON)
Servo (OFF)
Error Clear
Brake On/Off
ESC
OK
2. When both sensors are OFF, modify the value for front sensor of Drum position accessed from the Input parameter screen. • Adjust the front sensor value until the sensor height is level, with reference to the center of the plate edge, so that either the home or away sensor is ON. • When the plate is located at a position where both the home and away sensors are ON, adjust the front check position so that the plate is located at the position closest to the point where the sensors turn ON. 3850
CLR
Drum position [pulse] Lead clamp (load): Front Sensor: Tail clamp: Squeeze roller: Balancer pin: Pick up clamp: Tail clamp (unload): Length Sensor:
ESC
C-34
0 0 0 0 0 3 0 -15
SAVE
7
8
9
4
5
6
1
2
3
0
.
-
ENT
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
14. Replacement and adjustment procedure for the drum vacuum pressure sensor (P1) The following sensitivity adjustment is required after the drum vacuum pressure sensor is replaced. 1) Remove the front left cover, left side cover and rear cover from the PT-R4300. 2) Remove the sensor with its bracket and then remove the sensor from the bracket. (The sensor cannot be removed when the bracket is attached to the machine.)Re-attach the bracket after attaching a new sensor to it.
• Also remove the blower hose if necessary. • Do not remove the rubber packing from the bracket. Bracket Sensor
3) Fully rotate to the right the yellow trimmer (“HYS”) which is used for sensor sensitivity setting. 4) While the drum blower is OFF, rotate the blue trimmer (“SET”) which is used for sensor pressure setting and adjust it to the position where the indicator turns from ON to OFF. 5) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Blower (Drum) to ON.Confirm that the sensor indicator turns ON.If not, slowly rotate the blue trimmer (“SET”) to the left until the indica-
Blue trimmer (“SET”)
Yellow trimmer (“HYS”)
Indicator
tor turns ON. 6) Enter the Service/Maintenance Menu screen. → Enter the Actuator test screen. → Set Blower (Drum) to OFF.Confirm that the sensor indicator turns OFF.
Screwdrivers (cross-slot and small flatbladed types) L-shaped wrench (for M4 screws) Tie band
It will take a few seconds until the light turns OFF. 7) Turn OFF the power to the PT-R4300 and reattach the removed covers.
Nipper Approximately 30 minutes PT-R4300 SERVICE MANUAL
C-35
C.Replacement & Adjustment
15. Replacement and adjustment procedure for the plate sensor (PH6)(2 plates wind,or float)(Ser.No.–0100) The following sensitivity adjustment is required after the plate sensor is replaced. 1) Turn OFF the power to the PT-R4300 and remove the rear cover. 2) Turn ON the power to the PT-R4300 to initialize the machine. 3) Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Select Adjust Displatement sensor and press OK. 4) After stop the drum rotate,two screw loose and adjust the sensor.
Don’t loosen
Sensor position is sound. Point: The height is showed as two digits on the operation panel. The appropriate value is within the range D2 to DC. One pulse is 10 microns. 5) Press the “cancel” key. 6) Adjust the sensor offset
Adjust this way Loosen this screw
→ Select the plate type. → Input -9.99 on Displacement offset. (This is the mode to get the offset.) → Load a plate. Adjust the offset if the thickness is different just in case even though the same type of plate. 7) Turn OFF the power to the PT-R4300 and reattach the removed covers.
L-shaped wrench (for M4 screws) Nipper Interlock release jig Approximately 1 hour C-36
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment Ser.No.0101 For PT-R4000s with serial numbers 100 and earlier, the reference surface for detecting multiple plate feeding (plate looseness) was on the surface of the recording drum. However, with this setting, the offset value (Displacement offset) did not match the predetermined one (0.8 or less) and, thus, adjustment of the sensor height and replacement of the sensor was required during integral adjustment. For PT-R4000s with serial numbers 101 and onward, a black delustering seal has been attached to the drum and the reference surface for detecting multiple plate feeding (plate looseness) has been specified as the surface of the seal to stabilize the offset value. Therefore, perform the following adjustment procedure when there is any problem relating to replacement of the multiple plate feeding sensor or the sensor itself.
Black delustering seal
Leading edge clamp (third clamp from the Home side)
1) Preparation Turn ON the power to the PT-R4000, remove the rear cover, and enter the Service/Maintenance menu screen. → Enter the Drum test screen. → Bring the leading edge clamps near the plate top
30mm
35mm
side detection sensor, as shown in the figure on the left, and execute Servo ON. 2) Attaching a seal Attach a black delustering seal to the surface of the drum beneath the third leading edge clamp from the Home side.
Plate top side detection sensor (PH29H)
Recording drum
• Choose the attachment position of the seal carefully to prevent it from being covered by the leading edge clamps. • The surface of the recording drum must be cleaned prior to attaching the black delustering seal. Reference) Parts code: 100005768V00 Name: Black delustering seal (55 x 30 mm)
PT-R4300 SERVICE MANUAL
C-37
C.Replacement & Adjustment 4100
CLR Mfg.no(high):
58180
Mfg.no(low):
9
Mfg.year:
99
Mfg.month:
9
Machine type 2:
8
Machine type :
2
ESC
7
8
9
4
5
6
1
2
3
0
.
-
3) Changing the parameter value Enter the Service/Maintenance menu screen. → Enter the Input Parameter screen. → Enter the Set misc. data screen. → Enter “2” for “Machine type” and then press the SAVE key.
ENT
SAVE
For the “Machine type” parameter, “2” is set as the command to change the sensor detection reference to the seal, therefore, this parameter must be set to “0” when the seal is not the reference surface (i.e. it is on the drum surface as before). 4451
Front sensor offset
4) Adjusting the sensor height Centering test Adjust displacement sensor
Adjust the sensor height using the following command. Enter the Service/Maintenance menu screen. → Enter the Special action screen.
NVRAM backup NVRAM restore
→ Adjust Displacement sensor ESC
OK
NEXT
Once the drum has stopped rotating, loosen the sensor fixing screws (2 pcs.) and move the sensor up and down until a buzzer sounds. Then, tighten the fixing screws. The buzzer sounds near the point at which the con-
Don’t loosen
trol panel shows “A0”. Finally, press “cancel” on the panel to complete. Point: The height is showed as two digits on the operation panel. The appropriate value is within the range 9b to A5. One pulse is 10 microns.
Note that when “Adjust Displacement sensor” is Loosen this screw
C-38
Adjust this way
executed, the recording drum starts rotating toward the predetermined position.
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 1101
CLR Thickness
0.24 mm
Front offset 0.00 displacement offset -9.99 ESC
7
8
9
4
5
6
1
2
3
0
•
OK
ENT
Inputting -9.99 here brings you into the mode to obtain the offset value.
5) Re-obtaining the offset value Set media type → Input -9.99 to Displacement offset and save it. (This brings you into the mode to obtain the offset value.) → Load a plate onto the drum. → Reenter the Set media type screen and then the Displacement offset screen to check that the offset value has been changed. (The offset value should have been changed to 0.1 or lower.)
• Adjust the offset value when you use plates of the same size which have different thicknesses. • To clean the seal, wipe it using alcohol. Do not use thinner.
PT-R4300 SERVICE MANUAL
C-39
C.Replacement & Adjustment
16. Balancer weight replacement procedure. 1) Turn ON the power to the PT-R4300. → Enter the Service/Maintenance Menu screen. → Enter the Recording head test screen. → Enter the RH positioning screen. → Input 200 mm and press OK. (This facilitates observation of the balancer movement.) Calibration Sensor
It is not necessary to do this procedure when replacing the balancer weights at Away side. 2) Turn OFF the power to the PT-R4300 and remove the front cover and the right side cover. Then, remove the calibration sensor. 3) Remove the inside ring from the drum, which has the embossment going to the drum side near the screw. 4) Remove the outside ring in combination with the inside ring removed.
Emboss
5) Replace the balancer weight. 6) Put back the rings. Press the balancer weights Inside Ring Outside Ring
against the outer side of the guide groove. 7) Put back the calibration sensor. 8) Turn on and initialize the machine. And turn the drum by hand to confirm that the sensor detects the sensor dog with the weight. (The sensor lamp turns on when detecting.) If the sensor does not seem to work correctly, the sensor dog might be bent or its position is incorrrect, so ad-
Balancer Weight
just the dog. 9) Make sure that it works following procedure “3. Auto balacner weight detecting sensor adjustment”. 10) Put back the covers. L-shaped wrench (for M4 screws) Screwdriver (cross-slot type) Interlock release jig Approximately 30 minutes
C-40
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
17. Balancer motor unit replacement procedure. 1) Make sure that the machine is turned off and remove Balancer motor unit
the right side cover.
when replacing the away side motor, remove the front cover. 2) Remove the sensor unit first and then remove the balancer motor unit. 3) Install the new balancer motor unit.
Sensor Unit
When installing the motor, it might be little hard because the spring of the balancer unit pushes out, but install it with pushing. 4) Put back the sensor unit. 5) Turn on and initialize the machine. 6) Enter the service/maintenance mode. → Actuator test → Confirm that Lock pin and Balancer pin work. L-shaped wrench (for M3 screws) Interlock release jig Approximately 20 minutes
18. Balancer sensor replacement procedure. 1) Make sure that the machine is turned off and remove the right side cover.
Remove the front covert when replacing the away side sensor. 2) Remove the sensor unit and replace the sensor. L-shaped wrench (for M3 screws) Interlock release jig Approximately 15 minutes PT-R4300 SERVICE MANUAL
3) Put back the sensor unit. 4) Enter the service/maintenance mode. → Actuator test → Confirm that Lock pin and Balancer pin work. C-41
C.Replacement & Adjustment
19. Path driving motor replacement procedure. 1) Make sure the machine is turned off and remove the left side, the back, the front the top covers.
Drive Motor Unit
To ensure safety, secure the transfer path with the fixing brackets before the operation. 2) Remove the drive motor unit.
The screws are under the motor unit. 3) Remove the gear from the old motor and install it on the new motor. 4) Install the drive motor unit on the main unit. 5) Turn on and initialize the machine. 6) Enter the service/maintenance mode. Adjust the drive motor gear engage.
→ Actuator test → Confirm that the path unit goes up and down.
• If it is noisy during it going up and down, adjust the drive motor gear engage. • Do not touch the gears while the path is operating. 7) Put back the all covers.
L-shaped wrench (for M4 screws) Interlock release jig Approximately 30 minutes C-42
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
20. Squeeze roller height adjustment One of the possible causes of plate looseness on the leading edge side is that the full length of the squeeze roller may not contact the plate at the same time. In this case, adjust the squeeze roller height according to the following procedure. Fulcrum bracket (Home side) Squeeze sideplate (Home side)
1) Preparation Turn OFF the power to the PT-R4300 and remove the right cover and the rear cover. 2) Check that the distance between the squeeze sideplate and the rectangular hole of the fulcrum bracket, as shown in the figure on the left, is the same on the Home and Away sides.
Measure the distance here.
Squeeze sideplate (Away side) Fulcrum bracket (Away side)
The distance on each side should be from 11 to 15 mm and the difference between the Home side distance and the Away side distance must be less than 0.5 mm. * The height from the recording drum to the squeeze roller is checked and adjusted by adjusting the distance between the squeeze sideplate and the rectangular hole of the fulcrum bracket.
Measure the distance here.
Put an M4 flat washer here.
3) Rotate the cleaning roller by hand to check whether it rotates smoothly. Next, remove the cleaning roller and rotate the squeeze roller by hand to check that there is no prob-
When the cleaning roller shaft is put under heavy load.
Cleaning roller
lem in the bearings. If you feel that the movement is abnormally heavy, the bearings probably need to be changed. Also ensure that the bearings are not detaching from the respective squeeze sideplates.
Name: Ball bearings Parts code: 70584384-00 PT-R4300 SERVICE MANUAL
C-43
C.Replacement & Adjustment 4) If the actual difference between the Home side distance and the Away side distance is outside of the range of tolerance mentioned in step 2), adjust the position of each bearing engaged with the clamp arm until the difference is within the tolerance. The distance can be adjusted independently on the Home and Away sides. Clamp arm Loosen these screws to change the bearing position. (Changing the bearing position alters the position of the arm that is engaged with the bearing and this affects the height of the squeeze roller.)
Bearing
Adjust in this direction (Home side) Clamp arm Loosen these screws to change the bearing position. (Changing the bearing position alters the position of the arm that is engaged with the bearing and this affects the height of the squeeze roller.)
Bearing
Adjust in this direction (Awayside)
Point: When adjusting the squeeze roller height, first shift the bearing so that the squeeze roller moves away from the recording drum. Then tighten the bearing fixing screws firmly, and move the squeeze sideplate by hand until the bearing reaches the appropriate position.
Squeeze roller
5) Rotate the recording drum by hand, while viewing the squeeze roller from the right side (encoder side) of the machine, to check the following. • The recording drum does not contact the leading edge clamp. • The distance between the leading edge clamp and the squeeze roller is at least 5 mm.
Leading edge clamp
The distance here must be 5 mm or more.
When the distance between the squeeze roller and the drum is narrower, you will hear some airflow noise during high-speed rotation of the recording drum.
C-44
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 6) Enter the Service/Maintenance Menu screen. → Enter the Special action screen. → Execute initialization of the PT-R4300. 7) Turn OFF the power to the PT-R4300 and reattach each cover and the cleaning roller. There is another possible cause of plate looseness in addition to that relating to the height of the squeeze roller. This occurs if you have used the PT-R4300 for a long time. Aluminum particles from the plate and also tape adhesive on the plate edge may have adhered to the squeeze roller, cleaning roller, and surface of the recording drum. Therefore, ensure that the following items are cleaned at the same time as you adjust the height of the squeeze roller. • Cleaning roller • Squeeze roller • Recording drum
PT-R4300 SERVICE MANUAL
C-45
C.Replacement & Adjustment
21. Loading Guide (1) Replacement and Adjustment Replace and adjust the loading guide (1) following the below step as the guide must be replaced once a year or every 20,000 plates.
This guide is not installed in the PT-R4300. Part Code: U1250064-00 Name: Loading Guide (1) A/S 3204
M52:Niproller
Up
Down
SL53:Shutter
Close
Open
M55:Path
Up
Down
SL58:Door open
On
Off
1) Confirm that the machine is OFF, and remove the top cover and the rear cover. 2) Turn ON the power to the PT-R4300 and execute the
ESC
→ Lower the transfer path. (Press the Down key once.)
OK
Loading Guide (1) Conveyor Path Unit
When the transfer path reaches slightly above the middle position, turn OFF the power supply.
Upper position
(Alternatively, remove the interlock release jig to stop the movement of the transfer path.)
dle Mid ion it pos
Side Alignment Unit
Sensor PH50
Actuator test command to lower the transfer path. → Enter the Actuator test screen.
This is the place where the conveyor path is stopped to replace the loading guide (1). This
r we n Lo sitio po
place is to do this work easily where the path unit is just above the side alignment unit.
Loading Guide (1)
Screws for Loading Guide (1)
Marking
3) Score a line on the bracket for the sensor PH50 below the loading guide (1) and remove the sensor.
4) Open the shutter by hand and make score a line before removing the guide. (Score a line along the place where the guide is fixed.)
There are four screws for this guide.
C-46
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 5) Loosen the top screws for the guide and remove the guide.
• It is good enough to loose the screws because the top portion of the guide has cutout. • The Discharge Guide has holes at its both ends so that your tool can access the screws for the Loading Guide (1) through these holes.
Top Screws
6) Replace to a new guide. Shutter
Diacharge guide
Fix Screws
Set the new guide under the head of screws that were loosened at the above step 5). 7) Fix the guide. Loading Guide (1)
Top Cutout portion
Conveyor Path Unit
When fixing, you must set the guide at the place where you scored the line at the step 4). 8) Turn on the machine and initialize it, and then have the path unit go down to the middle position and confirm the height of the guide at the middle position.
The appropriate height at the middle position is as high as the plate guide in the punch unit or a little higher than the plate guide. But if it is too Loading Guide (1)
high, a plate would snag at the punch unit when the plate is side aligned. You should confirm it with the user’s plate. 9) Put back the covers that were removed in the step 1).
Screwdrivers (cross-slot type) Hexagonal wrench (for M3 and M4 screws) Approximately 30 minutes PT-R4300 SERVICE MANUAL
C-47
C.Replacement & Adjustment
22. PT-R4300 Ball screw for Sub-scanning Replacement Procedure Please read and understand the following procedure before starting. This work is for only when you have to replace the ball screw on the PT-R4300 in the field. Basically the jig is necessary to set the screw, but this procedure describes how to set it without the jig. Please be careful not to get any damage to the screw while you work. [Necessary tools] T bar Allen key for M4 , a set of Allen keys (long type), a pipe for Allen keys, LD short connector, Head handle, Dial gauge (2 microns) with Magnet stand, Tie wrap (small) [Screw to be replaced] U1254043-00 Sub-scanning ball screw unit 1. Move the recording head to 350mm from the origin point by RH positioning command, and turn off the machine. 2. Remove the left and the right side cover and the front cover. 3. Remove the air hose guide and disconnect the hose. 4. Attach the LD short connector onto the relay board. 5. Disconnect the cables to the LD driver box. At this time, remove the each cable bracket fixed to the base (see the arrow.) And the following procedure would be easier if you keep the Peltier driver ( for cooling LD) power cable at the Peltier unit side after removing the fan cover of the driver box. 6. Remove the stay bracket from the base, too.
Stay bracket
7. After removing the head cover, fix the relay board at the head base to protect the flexible cable.
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PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 8. Loosen the 5 bolts fixing the head base by a long Allen key with the pipe for Allen key and attach the Head handles before removing the head.
The length of the only one screw at Zoom side is different from the others. 9. Remove the positioning pins and remove the head completely.
B
10.Remove the back cover (see the arrow). At this time, loosen the screws at the drum side by T bar Allen key. 11.Remove the blind cover on the die cast base. 12.Disconnect the connection with the LM guide (see A and B in right figure.) Do not loosen the screw C. One of the connections with the LM guide, which is the drum side,
A D
C
A
is fixed with disc springs. Regarding the connection with the ball screw, remove the screws (M6 X 2) at the vertical side of the universal joint seen from the window of the die cast base (see D in the right figure.) 13.The die cast base is disconnected from the ball screw and the LM guide, and remove the die cast base slowly. 14.Remove the coupling (screw side) for the sub-scan motor (M3 set screw, see Figure E) and remove the sub-scan motor from the screw. Remove it horizontally not to get any damage to the coupling.
Do not remove the mount for the angular bearing (See the below figure, Fix screw G). This mount is the criterion. Do not remove the bearing bracket at the driven side, either. For machines with serial numbers 0021 and onward, double M3 hollow set screws are used. 15.Remove the screws for the angular fixing ring (See the below figure F, M4 x 3), and remove the whole screw (including the bearing) from the mount. F
G PT-R4300 SERVICE MANUAL
E C-49
C.Replacement & Adjustment Angular fixing ring
Screw to be replaced (Shipped such as this)
(For height adjustment) 1. Insert the screw until the bearing stops at the mount by the opposite procedure which you removed the screw replaced. At the driven side, put the bearing onto bearing bracket. Fix the fixing ring onto the
Direction where the base is pushed Inside of the LM guide is the criterion
mount by even pressure. And then the parallel between the screw and the LM guide is reproduced. 2. The screw holes of the LM guide nuts and the holes of the die cast base should match. Please be careful of the universal joint position. The distance between the RH base and the angular bearing is approximately 100mm. As the inside of the LM guide is the criterion, insert screws into the base and fix the base pulling the base to the front. (See A (8 screws) and B(2 screws) in the former figure.)
100 mm
Before installing the RH base, check for any foreign material or burrs on the nut surface on the LM guide and the contact surface of the RH base. The nut at the drum side is fixed such as the figure. Prepare the one set disc springs face to face and 3 sets total, and insert the spacers and two washers are set at the both ends and insert a screw CAP screw 2 – M5 x 20 into this set.
For the PT-R4000II and later machines, the lower side washer is not included.
C-50
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 3. This is the height adjustment between the screw and the LM guide. The height of the screw at the mount as the criterion and the one at the universal joint portion must be matched. Set a dial gauge with magnetic stand on the polished surface of the die case base and look for the highest position of the screw at the mount side such as the figure, and set it as zero position of the dial gauge. 4. Keep the dial gauge position and move it to another polished surface of the die cast base so that you can measure the height of the screw at the universal joint from the die cast base window. At this time, the height difference between the mount side and the joint side must be within 10 microns. For the height adjustment, fix the screws at the joint side temporarily (see the arrows) and set the screw higher than the mount side and then get the appropriate height by hitting the screw lightly by a shock less hummer or something. 5. When you get the appropriate height, fix the screw completely. Rotate the screw from end to end to confirm there is no snag. 6. Set the blind cover on the die case base and set the thick washers between the die case base and the RH base, and set the back cover. At this time, do not fix the screws for the back cover, it means they should be loose. ( After set the recording head and fix its position by the positioning pins, then the back cover should be fixed.) 7. Put the recording head onto the RH base. Insert the positioning pins and decide the head position and fix it.
8. Fix the back cover. 9. Connect the cables in the head following the diagram attached on the head cover. At this time, be careful not to interfere the light axis by the cables.
PT-R4300 SERVICE MANUAL
C-51
C.Replacement & Adjustment 10.Remove the head handles and close the head cover. The head side covers must be fixed by using M3 x 5 cap screw with spring washer and flat washer (see the arrow.)
11.Connect the motor. The criteria are the positioning pins. ( The motor bracket is against the face of the
1
mount bearing.) Insert the coupling onto the axis and decide the
2
position. Do not force to the coupling.
Pin
Put back the recording head harness and remove the LD short connector. Turn on the machine and see the full stroke by RH positioning function under the actuator view to check if the sub-scan motor works correctly. And execute laser calibration for all channels at 2400 and 2000 dpi. If it is completed, it is good. If not, the head may be not against the positioning pin(s) when removing and putting back the head. And check the focus and the zoom. If they are not bad, output a tint 50% and check its unevenness level.
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PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
23. Countermeasure against registration deviation in PT-R4300 The procedure described in this document is for when a user makes a complaint about insufficient registration accuracy in the PT-R4300 (i.e., a plate is misaligned in the Y direction), and, as a further condition, the problem occurs at a frequency of about one plate per day. If the problem does not occur frequently (e.g., one plate per week), it may be caused by careless operation by the user when he/she handles the plate, and it may be eliminated by cleaning the guide plate, rollers, etc. The last page of this document describes the method for finding out whether the cause of this problem exists in the PT-R4300 or in the printing machine. [Required jigs and tools] Phillips, Allen key set, spanner wrench set, 300 mm and 150 mm scales, PC (including communication software; Hyperterminal for Windows) [Operation] Perform the following operations to check for registration deviation of the plate (i.e., the plate does not stably fit with the Home-side registration pin). 1) Check the height of the transport unit and adjust it if necessary (using the user's maximum sized plate). During the overall adjustment at the factory, the height of transport unit was adjusted using a “830 x 645 -0.3” plate. Using the user’s maximum sized plate, adjust the height of the transport unit to the correct height for inserting the plate. Open the right side cover. Manually open the leading edge clamps and then lower the transport unit to its lower limit. Set a plate and lower the nip roller in order to sandwich the plate between the rollers just like when the plate is actually inserted. Open the shutter and push the plate's trailing edge by hand until it reaches the proximity of the leading edge clamps, which were opened in advance. Adjust the height of the adjustment bolts so that the plate leading edge is flush with the drum (the plate comes in contact with the drum) at the gripper section of the leading edge clamps. Do not forget the original height position. It is not necessary to move the lower limit position sensor located on the transport unit. Operation: • From drum positioning to the opening of leading edge clamps Service/Maintenance Menu screen → Drum Test → Leading Clamp → Actuator Test → Lock Pin (Home) IN → Lock Pin (Away) IN → Drum Test → Servo Off → Actuator Test → Leading Clamp Down • Movement of the transport unit (after a plate has been set) Service/Maintenance Menu screen → Actuator Test → Nip Roller Down → Pass Down (two times) → Shutter Open To restore to the original state, select “Special Action” in the Service/Maintenance Menu screen and then select “Initialize”. PT-R4300 SERVICE MANUAL
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C.Replacement & Adjustment 2) Check the registration accuracy in the actual load sequence operation. Once a plate loading is started, the transport unit lowers, the leading edge clamps open, and then the nip roller for the plate transfer is released when the plate has been fed to a point approximately 3 mm from the registration pins. (This point is, when you observe the area around the leading edge clamps, the spot where the fed plate makes a brief stop. As a guide to further identify the 3 mm point, find the position where the unnotched plate edge nearly aligns with the pin edge.) Make sure that the nipped plate is released at this point. It will be easier to check the releasing position of the nip roller if you remove the punch debris guide. When the plate is misaligned: Correct the misalignment using the parameter for correcting the plate feed amount. This is the fourth parameter from the top of “Input Parameter - Set Correction Data” in the Service/ Maintenance Menu screen. Reducing the numerical value moves the plate away from the registration pins. 3740
R R R R
0.000
0.00 0.00 0.00
+
0.00
ESC
CLR
[%]
0.000 [mm] [mm]
7
8
9
4
5
6
1
2
3
0
.
[mm] [µ] [mm]
OK
ENT
Note that the plate feed amount may change when the transport unit height is changed. 3) Measure the physical relationship between the engine base and the frame. (For measurement points, refer to the attached diagram. Up to 420.)
• In the PT-R4000II (serial number 421 and onward), the engine base has been appropriately tilted with respect to the frame in the punch unit section, therefore, adjustment of their physical relationship is not required. • When checking positions, be sure that the optical head is located at its origin. • Forcibly tilt the engine base so that the plate touches the Home side pin first. In other words, shift the Home side of the engine base toward the front side. Accurately measure at the left and right measurement points, which are symmetrically positioned relative to the center point, the distance between the machined surface of the engine base (inside the cover of the clamp drive section) and the outer surface of the frame. (Use a scale for the measurement.) We will send a diagram regarding the measurement points. When the engine base and the frame are positioned in parallel, the standard distance is 162 mm. From the standard configuration stated above, move the Home side of the engine base toward the front side so that difference between the location of the Home side and the Away side is approximately 1 to 1.5 mm. Currently, as a factory setting, the Home side has been set to 163 mm and the Away side has been set to 162 mm. To shift the Home side, grip a black-plated hexagonal bar stay at the clamp drive section and turn the entire engine C-54
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment base. (This operation requires quite a lot of muscle.) The operations described above have established the relationship of the transport unit and the drum heights and also have positioned the plate in the Y direction. Consequently, plate adjustment in the X direction should be carried out. 4) Plate positioning check in X direction From the Home side, remove the second leading edge clamp so that the Home side registration pin can be checked individually, which will make it easier to check how much the plate has shifted. Remark: The leading edge clamp is easily removed when drum’s servo motor is ON, after the drum has been rotated to the position where the leading edge clamps are located above the leading edge detection sensor stay. Be careful not to apply any unnecessary force to the stay. The screws for the clamp are quite tight, as they were secured using medium strength lock-paint. Be sure to apply the lock-paint when you re-secure the screws. You will find springs inside the leading edge clamp. Be sure, when the clamp is attached, that the clamp’s protrusions enter into these springs. In order to input commands from the terminal, turn ON DIP switch 1 of the RCP board. Set the plate for checking the registration accuracy and, from the actuator test screen, lower the transport unit to the punch position. Execute the terminal software from the personal computer. Precautions for execution of Hyperterminal Enter any file name in the connection setting dialog and press OK. (A file name is determined.) → For the connection method, select the COM port to which the communication cable is connected (normally COM1). → In the port setting dialog, make the following settings: Bit/sec. Data bit
9600 8
Parity Stop bit
None 1
Flow control Hardware Once these settings have been completed, press OK and start up the Hyperterminal. Execute the side alignment terminal command. Subsequently, the shutter opens, a plate is fed, side alignment is carried out, punch holes are made (if necessary), the plate is pulled back while it is being nipped, and then the operation stops after the shutter is closed. *1 Execute this command after the transport unit has been lowered to the punch position.
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C.Replacement & Adjustment (When the side alignment is carried out after making punch holes) • PNC 4 Width Length The hexadecimal digit particular to the punch set up (see *2 below) Thickness (Make a space between parameters.) *2 When making only the positioning punches → C When making the positioning punches + No. 2 + No. 5 → 1E When making the positioning punches + No. 1 + No. 6 → 1D When making the positioning punches + No. 1 + No. 2 + No. 5 + No. 6 → 3F
(When no punch hole is made) • PNC 5 Width Length Thickness With the PT-R4000 Ver. 3.04 or later, the Service/Maintenance Menu screen includes a screen that allows the performance of the same operation from the computer. (Special action → Register test) Place the plate to check the registration status on the insertion table and then close the door. Select Register test and press OK, and the plate selection screen is displayed. Specify the type of plate that is placed on the table in this screen. Perform centering and punching of the plate. The processing is complete when the plate is restored to the insertion table. The registration status of the plate can be adjusted in this menu screen. 4452
Register test
ESC
OK
NEXT
Operation after punching Lower the transport unit to the drum position (from the actuator screen operation). Rotate the drum until it reaches the Leading Clamp position, insert the securing pins and open the leading edge clamps. Open the shutter, turn OFF the Load Clutch in order to facilitate manual roller rotation and then slowly lower the plate to the pin position for checking misalignment. At the same time, check that the plate first touches the Home-side registration pin. Remark: If any error occurs because the plate size was incorrectly entered, the transport unit returns to the origin point.No buzzer will sound.
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C.Replacement & Adjustment Operation: Transport unit Service/Maintenance Menu screen → Actuator Test → Pass Down → Terminal command Drum Service/Maintenance Menu screen → Drum Test → Leading Clamp → Actuator Test → Lock Pin (Home) IN → Lock Pin (Away) IN → Drum Test → Servo Off → Actuator Test → Leading Clamp Down → Shutter Open → Load Clutch OFF Restart operation Special Action → Initialize According to the amount of shift in the X direction, laterally shift the punch unit (by moving the positioning reference plate on the Home side) or push or pull the engine base at the Home side, in order to align the punch positions of the pin and plate (their centers must be aligned). Be sure, at this moment, to record the amount of tilt of the punch in the Y direction so that you can replicate this tilt. 5) Other checks • Check whether or not the amount of tilt of the optional punch is too large. Re-adjust using a tilt pin. • Check whether or not the plate is pressed too hard or the distance between the plate and positioning pins is too wide during side alignment. Re-adjust following the procedure sheet. [Summary] In order to stabilize the registration accuracy: The plate must touch the Home-side positioning pin first. The plate must align with the registration pins in the X direction. The plate must be released at the appropriate position (not too far or too close). To optimize the resistance when a plate (at the size that the user mainly uses) comes in contact with the drum surface, the transport unit height for the plate loading to the drum must be properly adjusted.
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C.Replacement & Adjustment [How to identify whether the PT-R4300 or the printing machine is the cause of the registration deviation] This section explains how to determine whether or not the registration deviation has occurred in the PT-R4300. Since the PT-R4300 uses only plates, it is not possible to measure it on the light table using a graduated microscope, which is the method used for the film setter. As the PT-R unit uses registration punch holes as a reference for checking registration deviation, observe the grid lines of overlaid plates on the Home-side and Away-side using a low power loupe (5x to 10x). Required items: 6.35 dia. register pin x 2 pcs., loupe (5x to 10x) Sample exposure: Expose (local exposure at 2400 dpi) the grid pattern over the full surface of a plate of the size used by the user. At least four plates are required per job. (Add more plates if necessary.) Align the plate with the registration pins as described below. Secure the register pins and secure the output plate that will be used as a reference. For the second plate and thereafter, cut out the leading edge corners on the Home and Away sides and overlay the plates on the reference plate. Then, using the loupe, measure the difference between the grid lines in the Y direction on the plate and the grid lines on the reference plate. When the grid pattern has been exposed at 2400 dpi, the width of each line is approximately 30 micron. Criterion for judgment: As plates are positioned in reference to the Home-side pin, if a plate is misaligned in the Y direction, it is also consequently misaligned in the X direction Therefore, you only need to check the alignment in the Y direction. Since the line width is approximately 30 micron., you can consider the registration in the PTR4000 to be accurate when the corresponding grid lines are aligned within one grid line width. If the above criterion is not satisfied, perform the corrective procedure for the registration deviation. Itmay be difficult to identify the registration deviation depending on the number of plates to be checked. Therefore, registration deviation may be discovered at the user’s site even though it did not occur during local exposure. In this case, check the sample of the registration deviation from the user and ask about the frequency of the problem in order to determine whether or not to conduct a corrective procedure. X direction AWAY
HOME
Approximately Tilt Y direction
Tilt Y direction
Cut along the line from
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PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment How to check the release position of the nip roller statically (befor Ver3.03) 1.
Set a plate on the conveyor unit.
2. 3.
Actuator Test → Path Down From PC PNC 4 Width Length C ← Execute the side alignment, the reference punch and the nipping
4.
e.g.) PNC 4 830 645 C Actuator Test → Path Down (The lowest place) Drum Test → Leading Clamp Actuator Test → Lock Pin (Home/Away) IN Drum Test → Servo OFF Actuator Test → Leading Edge Clamp Down → Shutter Open Motor Test → M50: Transport Roller (IN) Set the feed amount (standard distance 130mm) by changing “pulse” to “mm”. Set 50 at Speed mm/sec and execute it. Measure the distance between the reference pin (Home side) and the plate, and get the compensation.
This + or – value is the compensation for the feed amount 130mm. This is the ideal that a plate reaches the drum 3mm before the reference pin when the plate feed amount is set 130mm. For example, if the feed amount is 130mm and the plate reaches the drum 3mm before the reference pin, the compensation value is –3mm. However this procedure is just like a rule of thumb. Therefore, you should check by eye and adjust it by loading a plate actually.
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C.Replacement & Adjustment How to check the release position of the nip roller statically (Ver. 3.04 and Ver. 4. 00 onward) 1.
Set a plate on the conveyor unit.
2. 3.
Actuator Test → Path Down Special Action → Register Test (Centering, punching, and nip operation are executed.)
4.
Actuator Test → Path Down (The lowest place) Drum Test → Leading Clamp Actuator Test → Lock Pin (Home/Away) IN Drum Test → Servo OFF Actuator Test → Leading Edge Clamp Down → Shutter Open Motor Test → M50: Transport Roller (IN) Set the feed amount (standard distance 130 mm) by changing “pulse” to “mm”. Set 50 at Speed mm/sec and execute it. Measure the distance between the reference pin (Home side) and the plate, and get the compensation.
This + or – value is the compensation for the feed amount 130 mm. This is the ideal that a plate reaches the drum 3 mm before the reference pin when the plate feed amount is set 130 mm. For example, if the feed amount is 130 mm and the plate reaches the drum 3 mm before the reference pin, the compensation value is –3 mm. However this procedure is just like a rule of thumb. Therefore, you should check by eye and adjust it by loading a plate actually.
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C.Replacement & Adjustment
Outer Surface of the frame
Engine base measurement point (Home side)
“A” must be 1 to 1.5mm longer than “B”
Engine base measurement point (Away side)
Scale
Scale
Outer Surface of the frame
The physical relationship above is for the machines with serial numbers up to 420. PT-R4300 SERVICE MANUAL
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C.Replacement & Adjustment
24. Countermeasures for Registration Deviation on PT-R4000 (additional information) Revision of the twist of the conveyor unit Normally the Home side and the Away side of the conveyor path are parallel. If either of the two sides does not hit the hexagonal bolt on the engine base or a plate being loaded on the conveyor path is skewed more than 1 mm against the drum, the conveyor path must be adjusted to be the same height.
(The height of the left portion and the right portion of the guide before the punch are different.)
(Hexagonal Bolt)
To see the difference between the right and the left at the punch unit or the drum, you should put a plate on the conveyor path and lower the nip roller. At this time, the plate does not have any curl. The revised portion should be the conveyor drive unit at the Home side basically.
(Revised portion: Conveyor Drive Unit at Home side)
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PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment Confirmation of adjustment amount
Fulcrum Pin
Scale
1.
Measure the distance between the this side of the frame and the pin of the conveyor drive unit.
2.
After adjusting, confirm if the target amount changed. If you want to decline the Home side, shorten the distance. (If the distance is longer, the Home side is higher.)
Adjustment (Revision) Be sure that the conveyor path is at the origin point (the highest position) when adjusting. 1) If the amount to be adjusted is less than 2mm, adjust the nut portion of the ball screw. 1. Loosen the hexagonal nut and the hollow set (set screw). 2. Loosen the adjusting bolt for the nut plate, rotate it along the semicircular oblong. 3. Tighten the adjusting bolt for the nut plate and then tighten the hollow set and the hexagonal nut.
Adjusting bolt for the nut plate
The nut part of the ball screw
The hollow set and the hexagonal nut.
Criterion for Adjustment (Ldeal designed value) The nut of the ball screw can rotate a maximum of ± 44 degrees. The height of the transfer path can be moved vertically by approximately ± 0.6 mm at the nut position, approximately ± 1.6 mm at the punch position, and approximately ± 1.9 mm at the drum position. But in reality, it might be a little different because each machine has different spring reaction, gap or something.
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C.Replacement & Adjustment 2) If the amount to be adjusted is more than 2mm or it has already been adjusted at 1). 1. Remove the four screws. 2. Grab the ball screw portion and pull it to the arrow side to release the bevel gear engagement. 3. Rotate the ball screw and change the engagement, and then push the ball screw to engage the gear. 4. Fix the screws.
Screws
Screws
(Engagement portion) Pull and release the bevel gear engagement
Criterion of Adjustment: (Ldeal designed value) The one tooth shift of the bevel gear makes the height of the conveyor path change approximately 1mm at the punch unit and approximately 1.3mm at the drum up or down. But in reality, it might be a little different because each machine has different spring reaction, gap or something.
When either 1) or 2) is adjusted, the sensor (PH57) to detect the middle position of the conveyor path and the sensor (PH55) to detect the lower position of the conveyor path may be adjusted.
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C.Replacement & Adjustment
25. Procedure for replacing the PT-R4XXX transfer path spring Rear section stay
Weld nut
Arm side Transfer drive spring
Tension bolt Compression spring Tension plate
Transfer drive stay
1.
Set the transfer path at its highest position and secure it with the transfer path fixing brackets (transport fixing brackets).
2.
Remove the E-ring and the bearing, and pull the fulcrum pin on the arm side of the transfer path until one side of the spring is freed. Be careful during this process not to drop the bearing and the washer. (In some cases, a thrust washer may be used in the E-ring section.)
Fulcrum pin
E-ring
Fulcrum pin
Washer Bearing
3.
Remove the rear cover of the machine to bring the rear side of the transfer drive stay into
4.
view. Peel off the tape to remove the roll pin of the weld nut.
Tape Home side
PT-R4300 SERVICE MANUAL
Away side
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C.Replacement & Adjustment 5.
Loosen the nut and two cap bolts to remove the weld nut.
6. 7.
Remove the rear section stay that secures the transfer drive stay. Pull out the tension bolt, tension plate, compression spring, and spring from inside the transfer drive stay. Weld nut
Nut
Rear section stay Nut
Roll pin
8.
Hooked part
Replace the damaged (old) spring with a new one. Make sure to orient the new spring correctly (the hooked parts should be at the bottom). The size of the opening of the hooked parts varies. Attach the hooked part with a wider opening to the tension plate.
Wider opening
9.
Hook the other side of the compression spring on a piece of thin cord (e.g., vinyl).
Cord
Compression spring
10. Set the compression spring and the tension plate section into the transfer drive stay. 11. Attach the rear section stay. In this step, pull the cords that were attached to the tension bolt and the compression spring through their respective holes in the rear section stay. 12. Slide the weld nut onto the tension bolt temporarily. (This is to prevent the tension bolt from dropping.) 13. Slide the arm-side fulcrum pin through the spring and then secure it together with the bearing and the washer. Ensure that the fulcrum pin is set in the loop of the compression spring. 14. Screw the weld nut onto the tension bolt until the thread portion of the bolt that is coming through the nut is the same length as the nut. Then, draw a cord through the oblong hole in the weld nut. 15. Secure the weld nut with the cap bolt and then secure the end of the thread portion of the tension bolt with the nut. Be sure to align the face of the nut and the end of the thread portion. C-66
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment 16. Pull out the cord that is secured to the compression spring to create a loop on one side of the compression spring, and then insert the roll pin into it. This inserted roll pin goes into the oblong hole of the stopper. 17. Cut the cord and affix a piece of tape over the roll pin to prevent it from falling off. 18. Finally, remove the transfer path fixing brackets.
1. When pulling or inserting a fulcrum pin, it may be hooked by the burr of the E-ring groove. In this case, lightly tap only the fulcrum pin to move it through. 2. Remove the fulcrum pin from inside to facilitate attachment of the E-ring and washer. 3. When the Away-side rear section stay is removed, the transfer drive stay lowers a few mm due to its own weight. Therefore, remove the rear section stay while supporting the transfer drive stay. 4. The replacement procedure is the same on the Home and Away sides, however, do not perform the procedure simultaneously on both sides. Be sure to replace each spring individually. The design of the transfer drive spring has been improved from the machine with serial number 516. Order the spring using the new parts code when you replace it. New parts code: 70516755-01 (tension spring )
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C.Replacement & Adjustment
26. Procedure for replacing the LD block 1) Prepare the jig and the wristband shown on the left before replacing the LD block.
2) Turn ON the power to the PT-R4300 and initialize it. 3520
CLR 7
8
9
Service/Maintenance Menu screen and move the recording head approximately 250 mm toward the
4
5
6
Away side.
1
2
3
0
.
250.00 mm
ESC
START
3) Select “Recording unit test → RH positioning” in the
ENT
4) Turn OFF the power to the PT-R4300 and remove the covers to initiate the procedure.
If the following steps in the procedure are performed with the power ON, you will be in danger of loosing your eyesight. Be sure to turn OFF the power before starting the replacement procedure. 5) Connect the jumper connector to the relay board of the recording head.
With this connector, all LD pins are at the same electrical potential. If the cables are removed without connecting this connector, the LDs may be damaged by static electricity. 6) Remove the air pressure hose guide that is on the recording head.
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C.Replacement & Adjustment 7) Remove the two screws from the lower section of the relay board and open the relay board outward.
8) Remove the upper cover of the recording head. This cover has been secured with seven screws. • Front: 4 screws • Top right: 2 screws • Top left: 1 screw
Top left
Top right
9) Pull the upper cover toward you and remove it.
When the upper cover is removed.
10) Attach a jig for replacement to the LD block that needs to be replaced. Then, replace the LD block using the hexagonal wrench provided with the jig.
Be sure to use the hexagonal wrench that is provided with the jig for replacement when you remove the LD block. If a normal hexagonal wrench is used, the screw thread of the jig for LD block replacement may be damaged.
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C.Replacement & Adjustment 11) Attach the jig for replacement to a new LD block and mount it on the LD base.
Before attaching the new LD block, make sure no dust or dirt is adhered to the contact surface. If any dust or dirt remains adhered to the surface, the optical axis may be deviated and thus appropriate laser power cannot be obtained or the value of current may become excessively high. 12) Remove the short-circuit sheet that has been attached to the new LD block. 13) Clean the following lenses of the recording head, as dust adheres to them easily. • Stereographic projection lens • No. 1 Lens • Reflective mirror • Zoom lens collar Stereographic projection lens
No. 1 Lens Reflective mirror Zoom lens collar
Use a mixed solution of alcohol and ether at a ratio of 1:1 for cleaning. As the lens surfaces to be cleaned are wide, use lens cleaning paper, not cotton swabs. 14) Reattach the upper cover of the recording head and the air pressure hose guides to their original positions and then remove the jumper connector (LD short connector jig) that was connected to the relay board.
If you fail to remove the LD short connector jig, the LD or the relay board may be damaged. 15) Reattach all covers and initialize the PT-R4300. Then, check the operations and the exposure performance. • The Iopd value for the new LD is entered. • The ON time (laser lighting time) of the replaced LD is cleared. • All the LD channels are calibrated. If a mode is set that uses half of the channels, 32 ch exposure cannot be performed. C-70
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C.Replacement & Adjustment
27. Procedure for replacing and adjusting the power supply After replacing the DC power supplies, be sure to adjust the output voltages as follows. Power supply name Set voltage U1 (5V/100W) 5.00V ± 0.01V
Measurement point Between pins 1 and 2 of the X100 power supply con-
U2 (15V/75W)
15.00V ± 0.10V
nector for the RB31 board Between pins 1 and 4 of the XU22 connector for U2
U3 (-15V/75W) U4 (24V/300W)
-15.00V ± 0.10V 24.30V ± 0.10V
Between pins 1 and 4 of the XU32 connector for U3 Power supply terminal for U4
U5 (24V/150W): For PT-R4000/4000II 24.00V ± 0.01V Between TP8 and TP3 on the CON-PTR4 board U5 (24V/300W): PT-R4300 24.00V ± 0.01V
Between TP8 and TP3 on the CON-PTR4 board
U6 (-5V/300W) U7 (24V/100W)
Power supply terminal for U6 Between TP6 and TP3 on the CON-PTR4 board
-5.3V ± 0.05V 24.00V ± 0.10V
The PT-R4300 does not contain this power supply. U9 (24V/30W) 24.00V ± 0.10V Between TP6 and TP3 on the CON-PTR4 board Neither the PT-R4000 nor the PT-R4000II contains this power supply. For the PT-R4300, the U7 (24V/100W) has been removed and the power supply capacity for the U5 (24V/150W) has been increased to 300W. In addition, the U9 (24V/30W) has been added for use with the interlock circuit.
28. Procedure for replacing and adjusting the pulse motor driver Set the DIP switches as follows after replacing the pulse motor drivers PMD50 DSW1-1: SL-ON DSW1-2: F/R-ON DSW1-3: EX1-OFF DSW1-4: EX2-OFF DSW1-5: EX3-OFF PMD61 DSW1-1: SL-ON DSW1-2: F/R-ON DSW1-3: EX1-ON DSW1-4: EX2-OFF DSW1-5: EX3-OFF PMD2
DSW1-1: SL-OFF DSW1-2: F/R-OFF DSW1-3: Unchangeable ON DSW1-4: Unchangeable OFF DSW1-5: Unchangeable OFF PSW1 (S.SEL1)-9 PSW2 (S.SEL2)-9
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C.Replacement & Adjustment Adjustment procedure for PMD61 The electric current used for PMD61 exceeded the specification in order to allow use of the common driver for all units. This has been changed so that PMD61 now uses an appropriate electric current. When you replace PMD61, adjust it in accordance with the procedure below. Note that this adjustment has already been completed for machines with serial numbers 425 and onward before shipment. This adjustment has also been completed for the PT-R4300. The power supply capacity has also been increased for this model.
PMD61
PMD61 PHASE CURRENT ADJUSTMENT PROCEDURE 1. Turn off the main power. 2. Cancel the “Auto current down function”: Turn off the SL of DSW1 in the PMD61. 3. Preparation for checking the Voltage of “Vref”: Connect the voltmeter with check pins to measure the voltage between IS and 0V. 4. Turn off the interlock switch then turn on the main power. (Because it is necessary to turn on the 5V power for logic first.) 5. Turn on the inter lock switch then turn on the DC24V. 6. Setting the current of the motor : Adjust the IS voltage to 0.8V(=Motor current value: 1.3A). Refer to Fig.2. Target division of “VR-1”; from -3 to -4 * Attention : During this adjustment, motor should be stopped and don’t apply the pulse voltage.
While adjusting the current, make sure to stop the motor and to not apply a pulse voltage. Otherwise, the driver will be damaged. 7. Turn off the main power, and turn on the SL switch.
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C.Replacement & Adjustment
29. Procedure for replacing the AC servo driver (E1A) Perform the parameter setting and necessary adjustments as follows after replacing the AC servo driver. 1.
Parameter setting for the driver Turn ON the power to the machine and enter the service maintenance mode without performing initialization. Access the [Input parameter] screen. → Access the [Drum parameter] screen. → Execute [Initialize]. Turning OFF the power to the machine during the parameter setting may damage the driver, so do not turn OFF the power during the [Initialize] operation. Since some parameters become active after the machine power is restored, always turn OFF the power to the machine and turn it ON again after the parameter setting is finished.
2.
Speed command offset adjustment Turn ON the power to the machine and enter the service maintenance mode without performing initialization. Access the [Input parameter] screen. → Access the [Drum parameter] screen. → Execute [Adjust Offset].
3.
Gain adjustment for the PIO board (SVC circuit) Access the service maintenance mode. → Access the [Drum test] screen. → Execute [Zero return]. Access the [Input parameter] screen. → Access the [Drum parameter] screen. → Execute [Adjust Gain]. Adjust the “VR1” trimmer resistor on the PIO-PTR4 board (PIO-PTR4 (2) ) until the buzzer sounds. Press [Cancel] on the screen to complete the operation.
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30. Procedure for replacing and setting the inverter (U8) for the suction blower Perform the following setting after replacing the inverter for the suction blower. Make sure to complete the setting described below. 1.
Turn OFF the power to the machine and disconnect the “XBU1” connector in the blower
2.
unit. Turn ON the power to the machine and change the “C13” parameter. “00”: a contact (normal open) [NO] ↓
3. 4.
5.
“00”: a contact (normal close) [NC] Turn OFF the power to the machine and re-connect the “XBU1” connector. Turn ON the power to the machine and change the “A01” (Frequency destination setting) parameter. “01” → “00” Change the “A04” (Maximum frequency setting) parameter. “50”Hz → “60”Hz
6.
Change the “A03” (Base frequency setting) parameter. “50”Hz → “60”Hz
7.
Change the “B12” (Level of electronic thermal setting) parameter. “2.60” 2.6A → “3.10” 3.1A
8.
Change the “B21” (Selection of overload restriction operation mode) parameter. “01” : “ON” during acceleration and deceleration only ↓ “00”:Normally “OFF”
9.
Change the “95” (No-load current) parameter. “3a” 58% → “23” 35% Follow the procedure below to change the “C95” parameter as simply selecting it cannot change it. • First, change the “C91” parameter from “00” to “01”. • Change the “C94” parameter from “0000” to “fb0a”. • Then, change the “C95” parameter from “3a” to “23”. • Reset the “C91” parameter from “01” to “00”.
10. Change the “C03” (Function of terminal 3 setting) parameter. “02” CF1 (multispeed 1) → “12”EXT (external trip) 11. After setting all the parameters, remove the duct cover. 12. On the inverter operation panel, set the volume to MAX (maximum value in the clockwise direction).
C-74
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
When you check the input data after completing the setting, be aware of the following points. • When confirming the data that was input in step 9), the data will be initialized when you exit the mode for changing the data and this disables the operation. Therefore, be sure to input the data again. • When confirming data other than that input in step 9), the data will not be initialized when you exit the mode for changing the data. The procedures for changing the data are shown below. The following procedures show b84 data as an example in which the current value is changed from 00 to 01. The descriptions in appear in the inverter display. 0.0 Func. d01 (2) c-(2) b-Func. b01
(1) b21 Func. 01 (1)
The current value is displayed here. Change the data. Increase the value by pressing the key and decrease the
STR
value by pressing the key. Press the [STR] store key to store the setting data.
Func.
Press the [Func.] function key to recheck the setting data that
00
b21
has been changed.
00 Func. b-(1) c-(1) d01 Func. 0.0
Be sure to return to this status after changing the panel display on the inverter.
PT-R4300 SERVICE MANUAL
C-75
C.Replacement & Adjustment Error displays for the inverter If troubles occur with the inverter, the errors shown below appear on the panel and the inverter output is cut off. “Motor” in the following table implies a blower. Error display E 01
E 02
E 03
E 04
E 05
E 07
E 08 E 09 E 11 E 12 E 13 E 14 E 15 E 21 E 22
C-76
Trip
Contents
Over-current During constant speed, excessive current was applied to the inverter. This protection during was caused by a short circuit of the inverter output, a locking of the motor constant speed or another reason. The protection circuit went into operation and the inverter output was cut off. Over-current During deceleration, over current protection went into operation and the protection during inverter output was cut off. deceleration Over-current During acceleration, over current protection went into operation and the protection during inverter output was cut off. acceleration Over-current Due to a cause other than those indicated by E01 to E03, over current protection due to protection went into operation and the inverter output was cut off. another cause Overload The motor became overloaded due to the detection of the inverter output protection current, the inverter?s built-in electronic thermal function detected the situation, and the inverter output was cut off. Over-voltage The voltage of the converter section exceeded a certain level because protection excessive regenerative energy or excessive input voltage was supplied from the motor, or the load lessened rapidly during the operation of the overload control, and the inverter output was cut off. EEPROM error An error has occurred with the built-in memory of the inverter. This was caused by outside noise, abnormal temperature or another cause, and the inverter output was cut off. Under-voltage The inverter voltage lowered below the 150V to 160V range, and the protection inverter output was cut off. CPU error The built-in CPU operated improperly, an error occurred, and the inverter output was cut off. External trip The motor thermal function detected an error and the inverter output was cut off. USP error The power supply was turned ON while the inverter was being run, and the inverter output was cut off. Ground fault A ground fault was detected between the inverter output and the motor protection when turning ON the power supply, and the inverter output was cut off. nput over-voltage 100 seconds after the power supply was turned ON, an input voltage higher than the specified value was detected, and the inverter was cut off. Temperature trip The temperature of the inverter module is higher than the specified value and the inverter output has been cut off. CPU error The built-in CPU operated improperly, an error occurred, and the inverter output was cut off.
PT-R4300 SERVICE MANUAL
C.Replacement & Adjustment
31. Procedure for replacing the RCP2 board Flash memories (U4, U13, U15, U18) U15 and U18 are for the user data and the data unique to the PT-R4300. X 1 66
X 1 63
X 1 62
X 1 61
X 1 50 X 1 60
U4
X 1 59
U 13
U 14
X 1 58
TEST
NV RAM (U14) U 15
R O M fo r d e b u g in g
X 1 57
U 18
X 1 56
X 1 55
CPU
D IP S W 1 X 1 54 O FF O N
H L 1 -8
1
H L 9 -1 6
U 62 X 1 53
8
H L 17-24
ROM for ALTERA-FPGA (U62)
RESE T
H L 25-32 A LT E R A X 1 64 P LL
H L 33-40
X 1 67 X 1 51
H L 41-42
X 1 52
H L 43-51
PT-R4300 RCP2 board
PT-R4000II
PT-R4000
RCP2- PT-R4 U1254023-00
FLASH ROM (U4,U13) PROM (U62)
S0249 Ver.1.32 S0249 Ver.1.30 S0249 Ver.1.00 B8381
*1: The flash memories (U4, U13) are not included in the board for the PT-R4XXX(U1254023-00). *2: The RCP2 board with U4, U13, and U62 removed is the same board as for the PT-R4000/ 4000II/PT-R8000/8000II.
The NV RAM (U14) included in the RCP2 board stores the data for the exposure conditions, error logs, and consumables timer. When the RCP2 board is replaced, all data must be transferred to the new board. Follow the procedure described on the next page to transfer the data.
• The consumables timer data include the data of the plate winding count that is necessary for the maintenance contract (at a metered rate). As this is important maintenance contractual information, be sure to transfer it to the new board. • Be sure to prepare a PLCC removal tool to remove or attach the flash memories (U4, U13, U15, U18). If you forcibly remove or attach the flash memories, the memory sockets will be damaged.
PT-R4300 SERVICE MANUAL
C-77
C.Replacement & Adjustment 4451
1) Enter the Special action screen of the maintenance
Front sensor offset
mode and select NVRAM backup.
Centering test Adjust displacement sensor
Before executing step 1), set bit 2 of the DIP switch on the RCP2 board to ON.
NVRAM backup NVRAM restore
ESC
OK
NEXT
When bit 2 is set to OFF, a message allowing you change it to ON will be displayed. 2) The message shown on the left is displayed. Pressing
4451
Do you backup the data on NVRAM in Flash-Memory ?
the OK button initiates transfer of the NV RAM data to the flash memories (U15, U18). 3) After completing step 2), turn OFF the power to the PT-R4300 and replace the RCP2 board with a new one.
ESC
OK
CANCEL
Be sure to swap U4, U13, U15, and U18 between the new and old boards. 4451
4) After the replacement, enter the Special action
Front sensor offset
screen of the maintenance mode without performing initialization, and select NVRAM restore.
Centering test Adjust displacement sensor NVRAM backup
Before executing step 4), set bit 2 of the DIP NVRAM restore
ESC
OK
NEXT
switch on the RCP2 board to ON. When bit 2 is set to OFF, a message allowing you change it to ON will be displayed.
4451
Do you overwrite the data on NVRAM with the data backup in Flash -Memory ?
5) The message shown on the left is displayed. Pressing the OK button initiates transfer of the NV RAM data transferred from the old board to the flash memories (U15, U18) to the new NV RAM. 6) After completing the transfer process, be sure to set bit 2 of the DIP switch on the RCP2 board to OFF.
ESC
C-78
OK
CANCEL
7) Finally, check the consumables timer to ensure that the data has been transferred successfully.
PT-R4300 SERVICE MANUAL
D. Operation panel
Set Printing machine
Set plate
Set exposure mode
User maintenance
D.Operation panel
Set media type
Printing machine selection Comment input Grip direction selection (vertical/horizontal) Leading and trailing grip margin setting Image centering method selection Exposure start point correction (primary scanning direction and secondary scanning direction) Punch type selection Image position adjustment (primary scanning direction and secondary scanning direction) Plate number selection Comment input Plate size setting (width and length) Media type number selection Comment input Positive/negative selection Plate thickness setting Front offset (offset value for the leading edge detection sensors), Displacement offset (offset value for the displacement sensor) Distance limit (threshold value for the displacement sensor) Light intensity setting Drum rpm setting Focus value setting Zoom value setting Primary scanning direction length correction Auto/manual loading selection (when SA-L/MA-L is connected) Front/rear unloading selection (when units including the auto processor are connected) Output settings for mirror/normal image, positive/negative, single/multi Auto/manual loading selection (when SA-L/MA-L is connected) Rear unloading (when units including the auto processor are connected) Manual loading Manual unloading Test exposure Test exposure for light intensity adjustment Test exposure for drum rpm adjustment focus Test exposure for focus adjustment zoom Test exposure for zoom adjustment Test exposure for simultaneous adjustment of focus and zoom
D-1
1. Screen flow diagram (PT-R4000: Ver. 3.06/ PT-R4000II: Ver. 4.04/ PT-R4300: Ver. 1.00)
Main menu (when PT-R4300 is used independently)
1-1.Main menu (when PT-R4300 is used independently)
PT-R4300 SERVICE MANUAL
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
D-2
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
Test exposure
ETC User maintenance setting
D.Operation panel
PT-R4300 SERVICE MANUAL
Test exposure for simultaneous adjustment of light intensity and drum rpm Test exposure Exposure maintenance [No-plate] : Setting of whether to perform exposure without loading a plate : Setting of whether to perform exposure without lighting up the LD (laser diodes) [Full size] : Setting of whether to perform exposure while including the grip margins Teaching of plate size in the primary and the secondary scanning directions Set Date Time Punch for cleaning Consumable Timer Checking and setting of running time, actual running time, exposure time, and plate winding cycle Checking and setting of usage time of filters Checking of number of times the punch operates (Punch 1 to Punch 4) Checking of number of times the punch operates (Punch 5 to Punch 8) Language Laser power measure Laser calibration Cancel calibration Calibration info. Return error to host Option setting [Buzzer while trans]: Buzzer for rear unloading ON/OFF/LOUD [Mistake plate]: Plate that is loaded incorrectly Remove/Discharge [Inter leaf warning]: Warning of interleaf discharge OFF/10 sheets/•••/90 sheets/100 sheets [Preload button] ON/OFF/COUNTER [Empty warning]: Warning that no plates remain ON/OFF
PT-R4300 SERVICE MANUAL
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
Information
Version display Error log display (outline) Error log display (details)
Set punch name Service
D.Operation panel
D-3
D.Operation panel 1-2.Main menu (when SA-L/MA-L is connected) Main menu (when SA-L/MA-L is connected) Cassete exchange Set Cassete Set Remaining Set exposure mode User maintenance Set Printing machine Set plate Set media type Set punch name Service Information
D-4
PT-R4300 SERVICE MANUAL
Service menu Password input screen Sensor test Actuator test Drum test Motor test Recording head test
Machine env.: Environment temperature LD block: LD base temperature HEAD env.: Recording head peripheral temperature Fin: Peltier fin temperature Dew codens: Dew condensation sensor Laser power measure, checking for the cable disconnection Iopd-Iop Set Correction data R : Correction for image length in the secondary scanning direction R : Correction for exposure start point in the primary scanning direction R : Correction for exposure start point in the secondary scanning direction + : Correction for image position in the primary scanning direction : Tilt correction R : Correction of plate feed amount Reference Y size data: Compensation of drum cylindricality Vacuum threshold Max paper count:Setting of maximum number of interleaves that can be stored in the interleaf collection box
D.Operation panel
Input parameter
RH zero return RH positioning Focus zero return Focus positioning Zoom zero return Zoom positioning Peltier test Laser calibration LD ON Calibration position Move to cal.pos. Temperature
1-3.Service menu
PT-R4300 SERVICE MANUAL
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
D-5
D-6
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
Input parameter
Set Correction data Set preset plate type Drum base position Drum position
Calibration position Set punch data RH parameter
Lead clamp (load): Not used Front Sensor: Adjustment of the leading edge position of plate Tail clamp: Trailing grip margin correction Squeeze roller: Drum position correction relative to the position at which the squeeze roller is lowered Balancer pin: Drum position correction relative to the balancer Pick up clamp: Drum position correction relative to the pick up clamp Tail clamp (unload): Drum position correction relative to the position at which the trailing edge clamp is released Length sensor: Correction for plate size in the primary scanning direction : Cam follower position adjustment : Cam follower position adjustment (Home) : Cam follower position adjustment (Away)
Laser power setting/Setting of target laser power used for channel calibration (Lpw, Ip1, Ip2, Ip3) Laser power adjust/Precise adjustment of power of each LD channel (A and B) Laser power confirm/Checking of power of each LD channel (Pw1, PW2, PW3) Reference laser power/Checking of electric current used in the laser diode channel (Iop)
D.Operation panel
Punch adjust
Temp. offset: Temperature sensor correction
PT-R4300 SERVICE MANUAL
PT-R4300 SERVICE MANUAL
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
Input parameter
RH parameter
Temperature setting
Laser running time Writing times clear Board constant setting Auto calibration
Meas. period: Number of times exposure is performed before starting auto calibration Meas. Thd (%): Allowable range of measured light intensity Cal. period (Hour): Exposure time before starting auto calibration Iop warning: Warning for calibration Cal. low temp.: Minimum temperature for calibration (35): Temperature around the recording head (28): Temperature in the PT-R unit (22): LD base temperature (16): Temperature in the PT-R unit (17): LD base temperature ---: Password Grip: Adjustment of unexposed area in the leading grip margin After-Grip: Adjustment of unexposed area in the trailing grip margin
D.Operation panel
Set temp. warning
Temperature: LD base temperature control level Pelter ctl. Duty: Peltier control value Alarm level: Alarm level temperature value
D-7
D-8
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
Input parameter
I/O Read/Write Initialize data
Parameter set Status read Initialize Adjust offset Adjust Gain Set misc. data/ Display of miscellaneous machine information Machine type setting Machine type 2 setting Set resolution Set weight Set cassete data Paper pad suck (correction of pad position for securing interleaves) Paper pad nip (correction of pad position for discharging interleaves) Y size base A, B, C (reference value of plate in the Y direction when it is transferred from the SA-L or the MA-L unit) Zone-2 min. size (minimum size for zone area 2) Zone-3 min. size (minimum size for zone area 3) Zone-4 min. size (minimum size for zone area 4) motion para 1(correction of the plate pad operation) Password for spec. func Network(OFF/PPP) LD/Stocker(OFF/LD/Stocker/ATM) CASSETE(OFF/Single/Multi3/Multi4/Multi5) Valid LD channel(32ch/0-15/16-31)
PT-R4300 SERVICE MANUAL
Initialize all data Select brand Initialize user data Consumble Timer Initialize preset media
D.Operation panel
Machine option select
Drum parameter
PT-R4300 SERVICE MANUAL
< > Provided in the parentheses are the page numbers on which a more detailed description can be found.
Special action
Special action 2
D.Operation panel
Initialize Ititialize machine status Pick up clamp Check ORG-EZ Put clamp on drum Front sensor offset Centering test Adjust Displacement sensor NVRAM backup NVRAM restore Register test Initialize Balancer test Mail test Auto loader test Plate pad test Paper pad test Multi auto loader test
D-9
D.Operation panel
2. Startup of the main unit without performing initialization After turning ON the power to the main unit, simultaneously press the two areas indicated by circles on the
0101
P T- R 4 3 0 0
screen shown on the left. Please press [START]
START
’02.05.01 V1.00
The screen shown on the left appears without an initialization of the main unit being performed.
0200
Not initialized 1 : 1: Plate 1
OFFLINE
OPEN
When starting up the main unit without performing initialization, the main unit does not operate normally. To operate the main unit normally, make sure to turn OFF/ON the power to the main unit or perform initialization from the operation panel.
D-10
PT-R4300 SERVICE MANUAL
D.Operation panel
3. Detailed descriptions of the Service/Maintenance screens 3-1.How to enter the Service/Maintenance Menu screen 0301
Service
Pressing the Service
Infomation
OK
key after selecting the
key brings up the Password Input
screen.
Set punch name Service ONLINE
OK
NEXT
3000
CLR 7
8
9
4
5
6
1
2
3
0
•
key again. The following Service/Maintenance Menu screen appears. OK
Pass Word 0
ESC
When the screen shown on the left appears, enter the ENT password, press the key and then press the
OK
ENT
The password is PT-R4000 (II): 4000, PT-R4300: 4300
3050
If you enter the wrong password, the screen re-
Sensor test
turns to the upper layer Menu screen (as indicated above).
Actuator test Drum test Motor test
You can set the maintenance parameters using the screens shown on the left.
Recording head test ESC
OK
NEXT 3051
NEXT NEXT
Input parameter Machine option select I/O Read/Write Initialize data Special action
ESC
OK
NEXT 3052
ESC
NEXT NEXT
Special action 2
OK
PT-R4300 SERVICE MANUAL
NEXT
D-11
D.Operation panel 3-2.Service/Maintenance Menu screens 3050
Sensor test
Sensor test
Drum test
Allows you to execute a sensor test. (Refer to D-14)
Motor test
Actuator test
Actuator test
Allows you to execute an actuator test.
Recording head test ESC
OK
NEXT
(Refer to D-19) Drum test
NEXT
3051
NEXT
Input parameter
(Refer to D-24)
Machine option select
Motor test
I/O Read/Write
Allows you to test the transport/discharge motors and
Initialize data
the plate side alignment motors. (Refer to D-26)
Special action ESC
OK
Allows you to execute tests for drum positioning and drum rotation.
NEXT
Recording head test
Allows you to execute tests and operations related to NEXT
3052
NEXT
Special action 2
the recording head. (Refer to D-29) Input parameter
Allows you to input and check parameter settings. (Refer to D-45)
Machine option select ESC
OK
NEXT
Allows you to set optional parameters for the machine. (Refer to D-87) I/O Read/Write
Allows you to execute I/O port data reading and writing. (Refer to D-88) Initialize data
Allows you to initialize parameter settings and change the machine “brand” name. (Refer to D-89) Special action
Allows you to execute special actions, including trailing edge clamp installation and initialization of the machine status. (Refer to D-94)
D-12
PT-R4300 SERVICE MANUAL
D.Operation panel Special action 2
This is a jig command for the auto loader. (Refer to D-104)
PT-R4300 SERVICE MANUAL
D-13
D.Operation panel 3-3.Sensor Test screens 3050
Sensor test
Sensor test
With this command, you can check the operating status of each sensor.
Actuator test Drum test
Sensor test Pressing the key after selecting the OK key brings up the Sensor Operation Check
Motor test Recording head test ESC
OK
NEXT
screen. In this screen, the indicators for the sensors that are currently ON appear highlighted. Sensor indications after the PT-R is initialized. Transmission type sensor: Turns ON when the light is blocked. Reflection type sensor: Turns ON when the sensor detects the specified conditions. ESC
Returns you to the upper layer Menu screen. NEXT
Switches to the next screen. (The NEXT key switches the display among the Sensor Selection screens.) After selecting the number of the sensor for which you want to check the operating state and pressing the OK key, you will hear a beep sound when the selected sensor turns ON.
D-14
PT-R4300 SERVICE MANUAL
D.Operation panel 3100 11 PH10H
6
PH11A2
11
PH27-1
16
PH30H
2
PH10A
7
PH20
12
PH27-2
17
PH30A
3
PH11H1
8
PH21
13
PH27-3
18
PH31H
4
PH11H2
9
PH24-1
14
PH29H
19
PH31A
5
PH11A1
10
PH24-2
15
PH29A
20
ESC
OK
NEXT
PH10H
: Balancer weight detection sensor (Home)
PH10A : Balancer weight detection sensor (Away) PH11H1 : Balancer pin position detection sensor 1 (Home) PH11H2 : Balancer pin position detection sensor 2 (Home) PH11A1 : Balancer pin position detection sensor 1 (Away) PH11A2 : Balancer pin position detection sensor 2 PH20
(Away) : Trailing edge clamp arm origin sensor
PH21
(Home) : Trailing edge clamp arm end point sensor
PH24-1
(Away) : Trailing edge clamp hook sensor 1
PH24-2 PH27-1
: Trailing edge clamp hook sensor 2 : Trailing edge clamp presence detection
PH27-2
sensor 1 : Trailing edge clamp presence detection
PH27-3
sensor 2 : Trailing edge clamp presence detection
PH29H
sensor 3 : Plate top side detection sensor (Home)
PH29A PH30H
: Plate top side detection sensor (Away) : Leading edge clamp close origin sensor
PH30A
(Home) : Leading edge clamp close origin sensor
PH31H
(Away) : Leading edge clamp close end point sen-
PH31A
sor (Home) : Leading edge clamp close end point sensor (Away)
PT-R4300 SERVICE MANUAL
D-15
D.Operation panel 3101 11 PH50
6
PH55
11
PH62
16
SB60-4
2
PH51
7
PH56
12
PH63
17
SB60-5
3
PH52
8
PH57
13
SB60-1
18
SB60-6
4
PH53
9
PH61H
14
SB60-2
19
PH58
5
PH54
10
PH61A
15
SB60-3
20
PH59
ESC
NEXT
OK
PH50
: Plate pass sensor on the plate-loading path
PH51
: Sensor for detecting an interleaf on the back of the plate
PH52 PH53
: Nip roller origin sensor : Shutter origin sensor
PH54 PH55
: Plate pass sensor on the plate transport path : Transport path change lower limit sensor
PH56 PH57
: Transport path change upper limit sensor : Transport path punch position sensor
PH61H
: Sensor for detecting the Home side edge of a plate for side alignment
PH61A
: Sensor for detecting the Away side edge of a plate for side alignment
PH62
: Plate edge detection sensor for the punch unit
PH63 SB60-1
: Side alignment origin sensor : Punch 1 origin sensor
SB60-2 SB60-3
: Punch 2 origin sensor : Punch 3 origin sensor
SB60-4 SB60-5
: Punch 4 origin sensor : Punch 5 origin sensor
SB60-6 PH58
: Punch 6 origin sensor : Origin sensor of the motor for opening/ closing the operation door (for PT-R4300 only)
3102 11 PH2
6
LS57
11
PD_ERR
16
LS28
2
PH6
7
LS58
12
PD_BSY
17
S1
3
LS4H
8
PH70
13
+24V
18
4
LS4A
9
P1
14
+15V
19
5
LS56
10
INVALM
15
-15V
20
ESC
OK
NEXT
PH59
: Discharge path plate pass sensor 2 (for PT-R4300 only)
PH2 PH6
: Scanning origin sensor : Sensor for detecting multiple plate feed-
LS4H
ing or loose plate : Scanning start point limiter
LS4A LS56
: Scanning end point limiter : Operation door interlock switch
LS57
: Cover interlock switch (LS57-1,2,3)
LS58
: Main cover servo stop switch (LS58-1,2,SW58)
PH70 P1
: AT unit plate detection sensor : Drum vacuum pressure sensor
INVALM : Inverter alarm PD_ERR : Processor error PD_BSY : Processor busy +24V : 24V voltage check D-16
PT-R4300 SERVICE MANUAL
D.Operation panel +15V
: +15V voltage check
-15V LS28
: -15V voltage check : Hook lever switch
S1
(LS28-1,2,2,4,5,6) : Key switch for maintenance (for PTR4300 only)
PH90 PH91-1
3103 11 PH90
6
PH92-3
11
PH97-3
16
2
PH91-1
7
PH92-4
12
PH98-1
17
3
PH91-2
8
PH93-1
13
SB98
18
4
PH92-1
9
PH97-1
14
19
5
PH92-2
10
PH97-2
15
20
PH91-2 : Plate pad middle position sensor PH92-1 : Plate underside interleaf detection sensor PH92-2
ESC
NEXT
OK
3104 11 LS94-2
6
IN92
11
16
2
LS94-3
7
S90
12
17
3
LS94-4
8
13
18
4
P101-1
9
14
19
5
P101-2
10
15
20
ESC
OK
amplifier : Plate surface interleaf detection sensor and plate length detection sensor amplifier (in plate transportation section)
PH92-3 PH92-4
: Plate detection sensor 1 : Plate detection sensor 2
PH93-1 PH97-1
: Interleaf nip motor home position sensor : Cassette No. detection sensor
PH97-2 PH97-3
: Cassette No. detection sensor : Cassette No. detection sensor
PH98-1 SB98
: Interleaf pad home position sensor : Plate detection proximity sensor
LS94-2 LS94-3
: Bridge section cover 2 interlock switch : Maintenance cover interlock switch
LS94-4 P101-1
: Cassette existence detection sensor : Pressure sensor
P101-2 IN92
: Pressure sensor : Single/multi identification signal
NEXT
H : Single L : Multi S90
PT-R4300 SERVICE MANUAL
: Interleaf detection sensor 1 : Plate pad home position sensor
: Key switch for maintenance (for SA-L/ MA-L4300 only)
D-17
D.Operation panel 3105 11 SQ200
6
SQ212A
11
SQ213D
16
2
SQ200A
7
SQ212C
12
LS200E
17
3
PH93-1 SQ211A
8
SQ212D
13
LS206
18
4
SQ211C
9
SQ213A
14
SQ210A
19
5
SQ211D
10
SQ213C
15
SQ210
20
ESC
LS210E
: Chain drive home position sensor
SQ200A : Chain drive positioning sensor SQ211A : Cassette tray 1 positioning sensor SQ211C : Cassette 1 storage checking sensor SQ211D : Arm activation sensor for storage of first NEXT
OK
SQ200
cassette SQ212A : Cassette tray 2 positioning sensor SQ212C : Cassette 2 storage checking sensor SQ212D : Arm activation sensor for storage of second cassette SQ213A : Cassette tray 3 positioning sensor SQ213C : Cassette 3 storage checking sensor SQ213D : Arm activation sensor for storage of third cassette LS200E : Chain drive second end point switch LS206 : Cassette door sensor SQ210A : Arm travel end point sensor SQ210 : Arm home position sensor LS210E : Arm protrusion detection sensor LS220U : Lift’s over-travel upper switch
3106 11 LS220U
6
2
LS220L
7
3
PH93-1 SQ220
8
4
AC-Z
9
5
AC-P16
10
ESC
11
AC-AL
16
SQ200D
12
AC-BU
17
LS206A
AC-P2
13
SQ221B
18
LS206B
AC-P1
14
SQ222B
19
15
SQ223B
20
AC-P8 AC-P4
AC-C0
OK
LS220L : Lift’s over-travel lower switch SQ220 : Lift home position sensor AC-Z : AC servo motor Z phase detection AC-P16 : Lift position output 5 AC-P8 : Lift position output 4
NEXT
AC-P4 AC-P2
: Lift position output 3 : Lift position output 2
AC-P1 AC-C0
: Lift position output 1 : Lift positioning end
AC-AL AC-BU
: Lift drive motor error : Lift is moving.
SQ221B : Lift interlock 1 sensor SQ222B : Lift interlock 2 sensor SQ223B : Lift interlock 3 sensor SQ200D : Chain drive slowdown sensor LS206A : Cassette door 1 switch LS206B : Cassette door 2 switch
D-18
PT-R4300 SERVICE MANUAL
D.Operation panel 3-4.Actuator Test screens 3050
Actuator test
Sensor test
Drum test
With this command, you can check the operation of each actuator.
Motor test
Pressing the
Actuator test
Actuator test
Recording head test ESC
OK
NEXT
key after selecting the key brings up the Actuator OperaOK
tion Check screen. ESC
Returns you to the upper layer Menu screen. NEXT
Switches to the next screen. (The key switches the display among the Sensor Selection screens.) Pressing the On
OK
key after selecting any of
keys for the actuators you want to check performs the check(s). MBL1
3200
MBL1:Blower (Drum)
On
Off
BL40:Blower (Gas)
On
Off
M41:Compressor (Gas)
On
Off
Off
: Blower (Drum)
Turns on/off the blower for the plate suction on the drum. BL40 : Blower (Gas) Turns on/off the blower for the exhaust gas suction.
ESC
OK
M41
: Compressor (Gas) Turns on/off the compressor for the exhaust gas collection when exposing.
3201
M11H:Lock pin (Home)
Out
In
M11H:Blancer pin (Home)
Out
In
M11A:Lock pin (Away)
Out
In
M11A:Blancer pin (Away)
Out
In
ESC
OK
PT-R4300 SERVICE MANUAL
M11H : Lock pin (Home) Activates the lock pin on the Home side. M11H : Balancer pin (Home) Activates the balancer pin on the Home side. M11A : Lock pin (Away) Activates the lock pin on the Away side. M11A : Balancer pin (Away) Activates the balancer pin on the Away side.
D-19
D.Operation panel M20
3202
M20:Squeeze roller
Up
Down
M20:Trail edge clamp arm
Up
Down
Hold
Rele
Up
Down
M24:Trail edge clamp hook M30:Leading edge clamp
ESC
: Squeeze roller
Activates the squeeze roller. M20 : Trail edge clamp arm Activates the trailing edge clamp arm motor. M24 : Trail edge clamp hook Activates the trailing edge clamp hook drive motor
OK
M30
: Leading edge clamp Activates the motor for opening/closing the leading edge clamp.
M58
3203
M58:Door open
On
Off
BZ1:Buzzer
On
Off
PS2:Power supply(Servo pack)
On
Off
PS43:Power supply(LD)
On
Off
ESC
: Door open Activates the solenoid for the operation door.
(*1) (SL58 for the PT-R4300) BZ1 : Buzzer Activates the buzzer. PS2 : Power supply (Servo pack)
OK
Switches ON/OFF the excitation of the servo pack. When ON, the drum is held still. When OFF, the drum is released. PS43
: Power supply (LD) Activates the power supply for the laser diodes.
1) For PT-R4000 (II) Whenever you set Door open to ON, be sure to set it to OFF afterwards. The solenoid will remain ON until the Door open is set to OFF. 3204
M52:Niproller
Up
Down
SL53:Shutter
Close
Open
Up
Down
M55:Path
ESC
D-20
M52
: Niproller Activates the nip roller in the trans port unit.
SL53
: Shutter Activates the shutter.
M55
: Path Activates the transport unit.
OK
PT-R4300 SERVICE MANUAL
D.Operation panel SL59-1
3205
SL59-1:Load clatch
On
Off
SL59-2:Unload clatch
On
Off
: Load clatch
Activates the transport clutch (on the plate loading side). SL59-2 : Unload clatch Activates the transport clutch (on the plate unloading side).
ESC
OK
M60-1
3206
M60-1:Punch 1
On
Off
M60-2:Punch 2
On
Off
M60-3:Register punch(Home)
On
Off
M60-4:Register punch(Away)
On
Off
ESC
: Punch 1
Activates Punch 1. M60-2 : Punch 2 Activates Punch 2. M60-3 : Register punch (Home) Activates the registration punch. M60-4 : Register punch (Away)
OK
Activates the registration punch. 3207
M60-5:Punch 5
Up
Down
M60-6:Punch 6
On
Off
M93:Paper nip roller
Up
Down
M90:Paper transport roller
On
Off
SL97:Carrier lock
On
Off
VP100:Vacuum pump
On
Off
ESC
M60-6 : Punch 6 Activates Punch 6.
OK
3208
ESC
M60-5 : Punch 5 Activates Punch 5.
OK
PT-R4300 SERVICE MANUAL
M93
: Paper nip roller Activates the interleaf nip roller.
M90
: Paper transport roller Activates the interleaf discharge roller.
SL97
: Carrier lock Activates the cassette lock. (only SA-L)
VP100 : Vacuum pump Activates the vacuum pump.
D-21
D.Operation panel V102-1
3209
V102-1:Plate pad valve 1
Close
Open
V102-2:Plate pad valve 2
Close
Open
V102-3:Plate pad valve 3
Close
Open
V102-4:Plate pad valve 4
Close
Open
ESC
: Plate pad valve1
Activates the solenoid valve operation for plate pad (zoon1). V102-2 : Plate pad valve2 Activates the solenoid valve operation for plate pad (zoon2). V102-3 : Plate pad valve3
OK
Activates the solenoid valve operation for plate pad (zoon3). V102-4 : Plate pad valve4 Activates the solenoid valve operation for plate pad (zoon4). 3210
V102-5:Paper pad valve 1
Close
Open
V102-6:Paper pad valve 2
Close
Open
V102-7:Paper pad valve 3
Close
Open
V102-8:Paper pad valve 4
Close
Open
ESC
OK
V102-5 : Paper pad valve1 Activates the solenoid valve operation for interleaf pad (zoon1). V102-6 : Paper pad valve2 Activates the solenoid valve operation for interleaf pad (zoon2). V102-7 : Paper pad valve3 Activates the solenoid valve operation for interleaf pad (zoon3). V102-8 : Paper pad valve4 Activates the solenoid valve operation for interleaf pad (zoon4).
3211
SL209:Mal door M200:Lift motor -> Lift -> Cas
ESC
OK
Close
Open
On
Off
On
Off
SL209 : Mal door Releases the door lock of the multi-cassette unit.
After the door lock has been released, closing the door will automatically lock it. M200
: Lift motor -> Lift Moves the cassette transportation motor. : Lift motor -> Cas Moves the cassette transportation motor.
For the machine’s protection, the motor will not operate when the part is in a wrong position (e.g., when the height of the lift is not correct).
D-22
PT-R4300 SERVICE MANUAL
D.Operation panel M210
3212
M210:Arm motor -> Lift
Out
In
SL207:Lift brake
On
Off
: Arm motor -> Lift Moves the arm motor.
In order to protect the machine, once the motor has moved to the Out direction, the motor cannot ESC
OK
move again. In such a case, return the cassette to the multi-cassette unit side until the lock works. SL207
: Lift brake
Moves the electromagnetic brake used for the lift tray.
If the M220 servo is turned OFF, the brake cannot be released. (e.g., when an interlock is released and a door is opened)
PT-R4300 SERVICE MANUAL
D-23
D.Operation panel 3-5.Drum Test screens 3050
Drum test
Sensor test
Drum test
With this command, you can check each of the drum unit’s various operations.
Motor test
Pressing the
Actuator test
Drum test
Recording head test ESC
OK
key after selecting the key brings up the Drum Unit OpOK
NEXT
eration Check screen. ESC
Returns you to the upper layer Menu screen. 3300
NEXT Zero Return
Fast
Slow
Leading Clamp
Squeeze
Front check
Tail clamp
Edge sense
Servo (ON)
Servo (OFF)
Error Clear
Brake On/Off
ESC
Switches to the next screen. (The NEXT key switches the display among the Sensor Selection screens.) Pressing the
OK
key after selecting any of
the test items executes its operation.
OK
Pressing the
3350
OK
key after selecting any of the
above commands brings up the screen shown on the left.
Start OK ?
ESC
Returns you to the previous screen. ESC
OK
Cancel
OK
The drum starts the selected command operation. Cancel
Halts the current operation of the drum. Zero Return: Detects the drum (encoder) unit’s z-pulse point. Fast: Rotates the drum at the exposure speed. (The drum rotates at the speed used during the last image exposure.) Slow: Rotates the drum at the plate transfer speed. Leading Clamp: Moves the drum to the plate loading position where the leading edge clamps can be opened to load a plate. D-24
PT-R4300 SERVICE MANUAL
D.Operation panel Squeeze: Moves the drum to the position where the squeeze roller can be lowered. Front check: Rotates the drum to the position for the plate leading edge check when loading. Tail clamp: Moves the drum to the position where the trailing edge clamps can hold or release a plate. Edge sensor: Not used. Servo (ON): Prevents the drum from rotating. Servo (OFF): Prevents the drum from rotating. Error Clear: Clears errors in the servo. Brake On/Off: Not used. 1050
1
Plate 1
2
Plate 2
3
Plate 3
4
Plate 4
5
Plate 5
ESC
Tail clamp
The screen shown on the left for selecting plate size only appears if this command is selected. This is because the grip’s trailing edge clamp positions are controlled by the plate size. OK
NEXT
After you select the plate size, a confirmation screen asking you whether to execute the selected command appears.
PT-R4300 SERVICE MANUAL
D-25
D.Operation panel 3-6.Pulse Motor Test screens 3050
Motor test
Sensor test
Drum test
With this command, you can check the operation of the pulse motor.
Motor test
Individually activates each pulse motor.
Actuator test
ESC
Recording head test ESC
OK
Returns you to the previous screen. Pressing the OK key after selecting the pulse
NEXT
motor you want to check starts its operation. 3450
M50
M50:Transport roller(In)
Activates the transport motor on the plate loading side.
M50:Transport roller(Out) M61:
M50
ESC
OK
: Transport roller (In)
NEXT
: Transport roller (Out) Activates the transport motor on the plate un-
loading side. M61 : Activates the plate side alignment drive motor.
NEXT
NEXT
3451
M91:Plate pad motor
M91
: Plate pad motor Activates the plate pad drive motor.
M92
: Plate transport roller Activates the transportation motor of the AT
M92:Plate transport rollor M98:Paper pad motor M95:Lift motor
section. M98 : Paper pad motor ESC
OK
NEXT
Activates the interleaf pad drive motor. M95 : Lift motor Activates the lift drive motor.
D-26
PT-R4300 SERVICE MANUAL
D.Operation panel Distance setting button
Distance setting button Sets the distance units for moving the selected pulse motor. Repeatedly pressing this button
3400
CLR
0 0.0
ESC
7
8
9
4
5
6
1
2
3
0
.
changes the indication in the following order.
[pulse] [mm/sec]
[pulse]
Currently, this button cannot be used for any of the listed pulse motor tests.
ENT
OK
[mm]
3400
CLR
0.0
ESC
7
8
9
4
5
6
1
2
3
0
.
[mm] [mm/sec]
OK
(Allowable range: -999.9 to 999.9): Sets the distance to move the pulse motor in “mm”
[pulse]
0
(Allowable range: -9999 to 9999):
• To operate the pulse motor continuously, input “0” in both fields of the screen shown on the left and press the OK key. • If you want to execute the M61 command, enter the plate’s width in this field.
ENT
[pulse]
3400
init
• If there is no plate loaded on the drum when you execute the M61 command, an error appears. Therefore, be sure to set a plate on the drum before executing this command. init
ESC
OK
Returns the selected pulse motor to its home position for initialization. This button cannot be used with either the M50 and M54 command. 0.0 [mm/sec] (Allowable range: 0 to 999.9): Sets the operation speed of the pulse motor. Setting this parameter to “0” will operate the pulse motor at the default speed (normal operating speed). Only use this parameter if you want to operate the pulse motor at a different speed. Pressing the OK key after completing the setting brings up the screen for pulse motor operation shown on the left.
PT-R4300 SERVICE MANUAL
D-27
D.Operation panel 3452
OK
Operates or initializes the pulse motor. When the operation is completed, the screen for distance setting reappears.
Start OK ?
ESC
D-28
OK
Cancel
PT-R4300 SERVICE MANUAL
D.Operation panel 3-7.Recording Head Unit Test screens 3050
Recording head test
Sensor test
Drum test
With this command, you can check the operation of the recording head unit.
Motor test
Pressing the
Actuator test
Recording head test
Recording head test ESC
OK
NEXT
key after selecting the key brings up the Recording Head OK
Unit Operation screen. ESC
Returns you to the previous screen. NEXT
Switches to the next screen. (The NEXT key switches the display among the Sensor Selection screens.) 3505
RH zero return
RH zero return RH positioning
Returns the recording head to its home position. (Refer to D-31)
Focus zero return Focus positioning
RH positioning
Zoom zero return ESC
OK
NEXT
NEXT
NEXT
Positions the recording head at a desired point in the secondary scanning direction. (Refer to D-32) Focus zero return
Returns the focus motor to its home position. (Refer to D-31) Focus positioning
Positions the focus motor at a desired point. (Refer to D-32) Zoom zero return
3506
Returns the zoom motor to its home position. (Refer to D-31) Zoom positioning
Zoom positioning
Peltier test
Positions the zoom motor at a desired point. (Refer to D-32)
Laser calibration LD ON
Peltier test
Calibration position ESC
OK
NEXT
Executes an operation test for the Peltier unit. (Refer to D-33)
NEXT
NEXT
Laser calibration
Executes LD channel calibration. (Refer to D-34) PT-R4300 SERVICE MANUAL
D-29
D.Operation panel LD ON
Turns the laser diodes ON. (Refer to D-36) Calibration position
Adjusts the position of the calibration sensor. (Refer to D-38) 3507
Move to cal. pos.
Move to cal. pos.
Moves the recording head to the calibration position.
Temperature Laser power measure
(Refer to D-39)
Iopd-Iop
Temperature ESC
OK
NEXT
Displays the temperatures in the recording head and in the PT-R unit. (Refer to D-40) Laser power measure
Measures the laser power. (Refer to D-41) Iopd-Iop
Displays the value obtained by calculating Iopd - Iop. (Refer to D-44)
D-30
PT-R4300 SERVICE MANUAL
D.Operation panel 3-7-1.Zero Return screen for recording head unit/focus motor/zoom motor 3505
RH zero return
RH zero return
RH positioning
Focus zero return
Focus zero return
Zoom zero return
Focus positioning
Allows you to return the recording head unit, focus
Zoom zero return ESC
OK
NEXT
motor, and zoom motor to their home positions. Pressing the OK key after selecting any of the above keys brings up the zero return confirmation screen.
3515
ESC
Returns you to the upper layer Menu screen.
Zero return ?
ESC
START
START
Starts the zero return operation. When the zero return operation is completed, the Recording Head Unit Test screen reappears.
3516
Processing Now. Please wait !
PT-R4300 SERVICE MANUAL
D-31
D.Operation panel 3-7-2.Positioning screens for recording head unit/focus motor/zoom motor 3505
RH zero return
RH positioning
RH positioning
Focus positioning
Focus zero return
Zoom positioning
Focus positioning
Allows you to position the recording head unit, focus
Zoom zero return ESC 3506
OK
NEXT
motor, and zoom motor. Pressing the OK key after selecting any of the above keys brings up the position entry screen.
Zoom positioning
ESC
Peltier test
Returns you to the upper layer Menu screen.
Laser calibration LD ON Calibration position ESC
OK
NEXT
3520
CLR
0.00
ESC
7
8
9
4
5
6
1
2
3
0
•
mm
Screen display for RH positioning 3540
CLR 7
8
9
4
5
6
1
2
3
0
•
2080 [pulse]
ESC
START
START
key to start the positioning operation.
Allowable range RH positioning [mm]: 0.0 to 903.0 Focus positioning [pulse]: 101 to 4000
ENT
START
After inputting values for the positions of each ENT unit, press the key and then the
Zoom positioning [pulse]: 201 to 9970 • For the zero return operation, the home position is regarded as the absolute position “0”. • 1 pulse corresponds to about 1 µm movement for Focus positioning and Zoom positioning. When the positioning operation is completed, the Recording Head Unit Test screen reappears.
ENT
Screen display for Focus positioning and Zoom positioning
3521
Processing Now. Please wait !
D-32
PT-R4300 SERVICE MANUAL
D.Operation panel 3-7-3.Peltier Test screen 3506
Peltier test
Zoom positioning
Allows you to execute an operation test for the Peltier unit.
Peltier test Laser calibration
Pressing the
LD ON
Peltier test
Calibration position ESC
OK
NEXT
key after selecting the key brings up the Peltier Test Input OK
screen. ESC
Returns you to the previous screen. 3570
CLR
Peltier ctl. DAC 0
ESC
7
8
9
4
5
6
1
2
3
0
.
-
OK
A value ranging from 0 to 255 can be input in the “Peltier ctl. DAC” field. Values in the range from 0 to 255 correspond to Peltier drive voltages ranging from 0 to 12V.
ENT
3571
Pressing the OK key after inputting a value in this field activates the Peltier unit.
STOP
Processing Now Please wait !
Returns you to the previous screen. STOP
• When an “Error Exe20” is displayed (LD block Peltier test key temperature too high), the is used to identify whether the malfunction is in
the Peltier unit itself or in the board driving the Peltier unit. • To identify the source of the error, run the Peltier unit and check whether output occurs normally from the Peltier unit’s terminal box and whether the area where the dew condensation sensor is attached has cooled down.
PT-R4300 SERVICE MANUAL
D-33
D.Operation panel 3-7-4.Laser Calibration screen 3506
Laser calibration
Zoom positioning
Executes LD channel calibration. The operation for calibrating the laser diodes is
Peltier test Laser calibration
the same as that executed by the “Laser calibration” command from the User Setting Selection
LD ON Calibration position ESC
OK
NEXT
screen. Pressing the Laser calibration
OK
key after selecting the
key brings up the Resolution Selec-
tion screen. ESC
Returns you to the upper layer Menu screen. 3580
Press the
Resolution
key after selecting the resolu-
1200 dpi
2000 dpi
2400 dpi
tion at which you want to calibrate the laser diodes.
4000 dpi
2438 dpi
2540 dpi
The Channel Selection screen for selecting a laser diode channel appears.
ESC
OK
3581
CLR
LD No. (0-31 32 : ALL) 32
ESC
OK
START
7
8
9
4
5
6
1
2
3
0
.
-
Input the number of the laser diode channel you ENT want to calibrate, and then press the key.
ENT
0-31 : Calibrates only the selected channel. 32 : Calibrates all channels. Then, press the tion.
START
key to execute calibra-
It takes approximately 20 seconds to calibrate a channel. To calibrate all the channels, it takes approximately 3 minutes. When laser calibration is completed, the Recording Head Unit Test Menu screen reappears.
D-34
PT-R4300 SERVICE MANUAL
D.Operation panel 32-ch recording head Application
Definition
Iopd
Electric current to output the rated power of laser diodes
Iop
Electric current to light the laser diodes
Screen
Used as electric Service/Input parameter/RH current that determines the life parameter/Reference laser power of laser diodes
←
Service/Input parameter/RH parameter/Laser power confirm
32-ch recording head Warning
Iopd-Iop ≤ 50mA
Error
Iop = Iopd
PT-R4300 SERVICE MANUAL
D-35
D.Operation panel 3-7-5.LD ON screen 3506
LD ON
Zoom positioning
Turns the laser diodes ON at each resolution setting.
Peltier test Laser calibration LD ON
Although the laser diodes in the PT-R are not directly visible, NEVER operate them while the RH
Calibration position ESC
OK
NEXT
unit’s cover is open. Pressing the LD ON
key after selecting the
OK
key brings up the Resolution
Selection screen. ESC
Returns you to the previous screen. 3590
Select the exposure resolution for which the la-
Resolution 1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
ser diodes will be used, and then press the OK key. The Laser Power Setting screen appears.
OK
3591
Light Adjust 85.0 %
ESC
7 4 1 0 OK
CLR 8 9 5 6 2 3 · ENT
3592
CLR
LD No. (0-31) 0
ESC
D-36
START
7
8
9
4
5
6
1
2
3
0
•
Input the desired laser power, and then press the
ENT
key.
Then, press the OK key. The Channel Input screen for selecting the number of the LD channel to turn ON appears.
Input the number of the channel you want to ENT key. turn ON, and then press the START Press the key. The laser on the channel
you selected is then lighted.
ENT
PT-R4300 SERVICE MANUAL
D.Operation panel Pressing the
3595
STOP
key terminates the laser il-
lumination and returns you to the Recording Head Unit Test Menu screen. Processing Now. Please wait !
STOP
PT-R4300 SERVICE MANUAL
D-37
D.Operation panel 3-7-6.Calibration Position screen 3506
Calibration position
Zoom positioning
With this command, you can automatically detect and adjust the position of the calibration sensor board.
Peltier test Laser calibration LD ON Calibration position ESC
OK
Whenever you replace the RH unit and/or caliNEXT
bration sensor, be sure to use this command. Pressing the
3600
CLR
SEARCH
Caribration position -0.6
-0.6
7
8
9
4
5
6
1
2
3
[mm]
0 ESC
·
key after selecting the
Calibration position
key brings up the Calibration Sensor Position Detection screen. ESC
Returns you to the previous screen. SEARCH
Detects the position of the calibration sensor board.
ENT
SAVE
OK
3601
Processing Now. Please wait !
3600
CLR
SEARCH
Caribration position -0.6
1.0
7
8
9
4
5
6
1
2
3
[mm]
0 ESC
ENT
SAVE
3605
Save Data ? YES
ESC
D-38
·
NO
When detection of the calibration sensor board is completed, the Calibration Sensor Position Detection screen reappears. The resulting detection data is also displayed on this screen. SAVE
Saves the new data. Press YES and then OK to save the position of the calibration sensor board. If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-7-7.Moving to Calibration Position screen 3507
Move to cal. pos.
Move to cal. pos.
Allows moving of the recording head to the calibration position.
Temperature Laser power measure
Pressing the
Iopd-Iop
Move to cal. pos.
ESC
OK
NEXT
key after selecting the key moves the recording head to OK
the position where the calibration is executed.
When the recording head movement is completed, the menu screen shown on the left appears
3610
Processing Now. Please wait !
PT-R4300 SERVICE MANUAL
D-39
D.Operation panel 3-7-8.Temperature Display screen 3507
Temperature
Move to cal. pos.
Allows displaying of the temperatures in the recording head and in the PT-R unit.
Temperature Laser power measure
Pressing the
Iopd-Iop
Temperature
ESC
OK
NEXT
key after selecting the key displays the Temperature OK
screen. ESC
Returns you to the previous screen. 3620
Temperature Machine env. LD bolck Head env. Fin Dew condens
27.1 25.0 28.1 28.0 0
Temperature Machine env. : Displays the temperature in the PT-R unit. Warning status: Temperature in the PT-R unit > 28 °C or
OK
temperature in the PT-R unit < 18 °C LD block : Displays the LD base temperature. Error status: LD base temperature >28 °C Head env. : Displays the temperature around the recording head. Error status: Temperature around the recording head >35 °C Fin : Displays the temperature of a radiating fin. Error status: Radiating fin temperature > 55 °C Dew condens : Displays the dew condensation sensor status. (Unit: kW) Normal status: 0 to 20 kW Warning status: Over 20 kW Error (dew condensation) status: Over 100 kW
D-40
PT-R4300 SERVICE MANUAL
D.Operation panel 3-7-9.Laser Power Measurement and Cable Disconnection Check screens 3507
Laser power measure
Move to cal. pos.
Allows you to measure the laser power. OK Pressing the key after selecting the
Temperature Laser power measure
Laser power measure
Iopd-Iop
key brings up the Resolution Se-
lection screen. ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. Select the resolution by which you wish to measure the laser power and then press the
2260
Resolution
ESC
1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
key. The Laser Power Measurement screen appears. OK
OK
Then, press the
2261
OK
key to activate the laser
power measurement.
Start OK ?
ESC
OK
While the laser power is being measured, the display shown to the left appears.
2262
Processing Now. Please wait !
PT-R4300 SERVICE MANUAL
When the measurement of laser power is completed, the following screen appears.
D-41
D.Operation panel 2263
0ch 1ch 2ch 3ch 4ch 5ch 6ch 7ch
Target values (Lpw): 270 270 270 270 270 270 270 270
8ch 9ch 10ch 11ch 12ch 13ch 14ch 15ch
270 270 270 270 269 270 270 270
16ch 17ch 18ch 19ch 20ch 21ch 22ch 23ch
270 270 270 270 270 270 270 270
24ch 25ch 26ch 27ch 28ch 29ch 30ch 31ch
270 270 270 270 270 270 270 270
These values have been specified in the Laser power setting screen, which is accessible by selecting Service Maintenance → Input parameter → RH parameter. 1200 dpi: 240 mW/ch 2400 dpi: 240 mW/ch
OK
2000 dpi: 270 mW/ch 2438 dpi: 240 mW/ch
2540 dpi: 230 mW/ch 4000 dpi: 240 mW/ch The measured values are indicated in % in the
NEXT
user mode screen. Pressing
2264
0ch 1ch 2ch 3ch 4ch 5ch 6ch 7ch
100% 8ch 100% 9ch 100% 10ch 100% 11ch 100% 12ch 100% 13ch 100% 14ch 100% 15ch
100% 100% 100% 100% 100% 100% 100% 100%
16ch 17ch 18ch 19ch 20ch 21ch 22ch 23ch
OK
100% 100% 100% 100% 100% 100% 100% 100%
24ch 25ch 26ch 27ch 28ch 29ch 30ch 31ch
100% 100% 100% 100% 100% 100% 100% 100%
OK
brings up the screen shown on the
left. In this screen, you can make sure that the cables running from the RB31 board to the recording head are not disconnected. • When the measured light intensity is 50% or more of the target light intensity. • When the measured light intensity is less than 50% of the target light intensity. The measured values are indicated using
or ×
in the user mode screen.
1) Operation conditions The screen to check for the disconnection of image signal cables between the RB31 board and the recording head is displayed when the following conditions are satisfied. • The firmware version of the main unit is: PT-R4000 : Ver. 3.06 or higher PT-R4000II : Ver. 4.04 or higher PT-R4300 : Ver. 1.00 or higher • A plate has been loaded. • The Machine Type 2 parameter (Service Maintenance → Set misc. data) has been set to “4”. (Factory set value: 0) • The 16 ch exposure mode has not been set. 1) There is no disabled or lowered light intensity LD. 2) The 16 ch exposure mode has not been selected in the Service Maintenance → Machine option select screen.
D-42
PT-R4300 SERVICE MANUAL
D.Operation panel 2) Description of the operation The cable disconnection is checked by issuing a pseudo-image signal from the RB31 board to light up the LDs. The light intensity of each LD is measured using the calibration sensor. When the measured LD power is insufficient, the sensor identifies it as a cable disconnection. The check for cable disconnection can be performed only when the recording head is in the calibration position. 3) Timing of the check The cable disconnection check timing is: • After the regular light intensity measurement 1) Before exposing the first plate after turning ON the power supply 2) Before exposing a plate after completing exposure of 24 plates (default value) Note that if the output laser power of any of the LDs is out of the ± 5% (default value) range of the target output value, the cable disconnection will not be checked. 4) When the disconnection of any cable between the RB31 board and the recording head is detected: If the output laser power of any of the LDs is less than 50% of its target value, the following error will be issued. Ex839 The cable between RB31 board and recording head is disconnected. When this error is issued, the exposure operation is canceled and it can be resumed after resetting the error and performing an initialization.
PT-R4300 SERVICE MANUAL
D-43
D.Operation panel 3-7-10.Iopd - Iop screen 3507
Iopd-Iop
Move to cal. pos.
Displays the lives of the laser diodes according to the calculation.
Temperature Laser power measure
Pressing the
Iopd-Iop
Iopd-Iop
ESC
OK
NEXT
key after selecting the key brings up the screen to select OK
the resolution. ESC
Returns you to the upper layer screen. 3700
Resolution
Select the resolution and press the
1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
key.
OK
The values listed in the screen shown on the left
3701
0. 1. 2. 3. 4. 5. 6. 7.
OK
392 381 374 367 414 365 356 412
8. 9. 10. 11. 12. 13. 14. 15.
332 357 333 345 330 339 342 359
16. 17. 18. 19. 20. 21. 22. 23.
OK
353 394 412 386 393 394 387 408
24. 25. 26. 27. 28. 29. 30. 31.
408 399 329 401 407 418 400 408
indicate the results of following calculation formula. Iopd - Iop Indicated value ≤ 50 mA Life warning status of laser diode Indicated value > 50 mA Normal status of laser diode Indicated value = 0 mA Life error status of laser diode
D-44
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8.Input Parameter screen 3051
Input parameter
Input parameter
With this command, you can enter and change various parameters for the PT-R.
Machine option select I/O Read/Write
Pressing the
Initialize data
Input parameter
Special action ESC
3705
OK
NEXT
Allows you to set correction values for precisely adjusting the image length to be exposed on a plate (in the secondary scanning direction) and
Drum base position Drum position OK
Menu screen.
Set Correction data
Set Correction data
Set preset Plate type
ESC
key after selecting the key brings up the Input Parameter OK
NEXT NEXT
adjusting the exposure start origin. (Refer to D-47) Set preset Plate type
Allows you to register the data for preset plate types. (Refer to D-49) Drum base position
Allows you to correct for the deviation between the drum reference point and the encoder Z pulse point. (Refer to D-50) Drum position
Allows you to precisely adjust the positioning of the drum. (Refer to D-52) 3706
Punch adjust
Punch adjust Calibration position
Allows you to set a correction value for posi-
Set punch data
tioning the punch unit with reference to a plate’s center, and adjusts the spring tension in
RH parameter Drum parameter ESC
OK
NEXT NEXT
the plate side alignment unit. (Refer to D-54) Calibration position
Allows you to input a correction value for the position of the calibration sensor. (Refer to D-55)
PT-R4300 SERVICE MANUAL
D-45
D.Operation panel Set punch data
Allows you to set parameters for optional punch units. (Refer to D-56) RH parameter
Allows you to set parameters for the board and laser diodes in the RH unit. (Refer to D-57) Drum parameter
Allows you to set parameters for the drum motor driver. (Refer to D-73) 3707
Set misc. data
Set misc. data
The Mfg. No of the machine is already entered. (Refer to D-80)
Set resolution
Set weight
Set resolution
Set cassette data
Password for spec. func
ESC
OK
NEXT
Sets the address in the parameter table for registering the RH unit’s settings for each resolution. (Refer to D-81) Set weight
Sets the weights of the trailing edge clamps and the balancer. (Refer to D-82) Set cassette data
Sets the sizes of the plates to be used in the zones 2 and 3. (Refer to D-83) Password for spec. func
Sets the password for various special functions. (Refer to D-86)
D-46
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-1.Correction Data Setting screens 3705
Set Correction data
Set Correction data
Allows you to set correction values for precisely adjusting the image length to be exposed on a plate (in
Set preset Plate type
the secondary scanning direction) and adjusting the exposure start origin.
Drum base position Drum position ESC
OK
NEXT
Pressing the Set Correction data
key after selecting the key brings up the Correction Data OK
Setting screen. From this screen you can input correction values, precisely adjust the image length to be exposed on a plate in the secondary scanning direction, and adjust the exposure start origin. ESC
Returns you to the previous screen. 3740
R R
0.00 0.00 0.00
+
0.00
ESC
CLR
[%]
0.000 [mm] R
R
0.000
[mm]
7
8
9
4
5
6
1
2
3
0
.
-
R
length of an image exposed on a plate in the secondary scanning direction.
[mm] [µ] [mm]
OK
ENT
[%] (Allowable range: -9.999 to 9.999) This correction value precisely adjusts the
The correction value is used to adjust the image length exposed on a plate in the secondary scanning direction. For example, if an image which is 800 mm in the secondary scanning direction is exposed on a plate while this correction value is set to “0”, if the resulting length of the exposed image on the plate is 799 mm, the image deviation equals: (800 - 799)/800 x 100 = 0.125 (%) Inputting this value as the correction value above allows you to precisely expose an image on a plate with exactly the same length as its secondary scanning dimension. R
Input a correction value for the exposure start origin in the main scanning direction.
R
Input a correction value for the exposure start origin in the secondary scanning direction.
R
Input a correction value for the plate feed amount when loading. This setting can correct deviation from the standard pin position within a range of 50µm.
PT-R4300 SERVICE MANUAL
D-47
D.Operation panel +
Input a correction value for the image position in the primary scanning direction.
3741
Refarence Y size data 1. 0 9. 0 17. 0 2. 0 10. 0 18. 0 3. 0 11. 0 19. 0 4. 0 12. 0 5. 0 13. 0 6. 0 14. 0 7. 0 15. 0 8. 0 16. 0 ESC
CLR 7
8
9
4
5
6
1
2
3
0
•
It is not necessary to input any correction values. All data have been set to “0” at the factory.
ENT
OK
3742
CLR Vacuum threshold
30
Max paper count
30
-----------------
0
Temp. offset
0
ESC
This table is for inputting the cylindricality correction values.
7
8
9
4
5
6
1
2
3
0
. ENT
OK
Vacuum threshold: This value is used to chaeck that the vacuum hose has not been disconnected. Max paper count: (Allowable range: 0 to 100): Input the maximum number of interleafs that can be stored in the interleaf collection box. When the number of interleafs exceeds this value, a warning message indicating the interleaf disposal will be displayed. Temp.offset: [0.1°C] (Allowable range: -50 to 50): Input a correction value for the temperature sensor. For details, refer to “7.Temperature correction sensor adjustment” in chapter C.
3745
Press
Save Data ? YES
ESC
D-48
NO
YES
and then
OK
to save the setting
data. If you do not want to save the data, press and then
OK
NO
.
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-2.Preset Plate Type Setting screen 3705
Set preset Plate type
Set Correction data
Allows you to register the data for preset plate types. OK Pressing the key after selecting the
Set preset Plate type
Set preset Plate type
Drum base position
Setting screen.
Drum position ESC
OK
key brings up the Preset Plate Type
NEXT
ESC
Returns you to the previous screen. Select the number of the plate type option you
1057
31
FUJIFILM LH-PI 0.24mm
32
FUJIFILM LH-PI 0.30mm
33
FUJIFILM LH-NI 0.24mm
34
FUJIFILM LH-NI 0.30mm
35
KODAK IR 0.24mm
ESC
OK
NEXT
want to modify, and then change or correct its data. • The default plate type data has already been set in the factory before shipment. • For details on how to change or correct plate type data.
1058
36
KODAK IR 0.30mm
37
Media Type 37
38
Media Type 38
39
Media Type 39
40
Media Type 40
ESC
OK
PT-R4300 SERVICE MANUAL
NEXT
D-49
D.Operation panel 3-8-3.Drum Base Position Setting screen 3705
Drum base position
Set Correction data
Allows you to correct for the deviation between the drum reference point and the encoder Z pulse point.
Set preset Plate type
Pressing the
Drum base position
Drum base position
Drum position ESC
OK
NEXT
key after selecting the key brings up the Drum Base PosiOK
tion Setting screen in which you can correct the deviation (in pulses) between the drum reference point and the encoder Z pulse point. ESC
Returns you to the previous screen. 3840
CLR
READ Drum base position 1105
ESC
1105 [pulse]
7
8
9
4
5
6
1
2
3
0
·
ENT
SAVE
READ
Returns Detects the deviation (in pulses) between the drum reference point and the encoder Z pulse point.
Before using this
READ
command, be sure to in-
stall the drum positioning jigs. After completing the detection of the deviation
3841
between the drum reference point and the encoder Z pulse point, the screen shown on the
Drum base position 1309[pulse]
left appears. Press the
OK
key.
The resulting data is then displayed on the ESC
screen.
OK
3840
CLR
READ Drum base position 1105
ESC
D-50
1309 [pulse]
SAVE
7
8
9
4
5
6
1
2
3
0
·
SAVE
Allows you to save the new data.
ENT
PT-R4300 SERVICE MANUAL
D.Operation panel 3845
Press
Save Data ? YES
ESC
NO
YES
and then
OK
to save the result-
ing data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-51
D.Operation panel 3-8-4.Drum Position Setting screen 3705
Drum position
Set Correction data
Allows you to precisely adjust the positioning of the drum.
Set preset Plate type
Pressing the
Drum base position
Drum position
Drum position ESC
OK
NEXT
key after selecting the key brings up the Drum Position OK
Precise Adjustment screen. ESC
Returns you to the previous screen. 1 pulse = 0.28 mm 3850
CLR
Drum position [pulse] Lead clamp (load): Front Sensor: Tail clamp: Squeeze roller: Balancer pin: Pick up clamp: Tail clamp (unload): Length Sensor:
ESC
0 10 12 0 0 4 1 -5
SAVE
7
8
9
4
5
6
1
2
3
0
.
-
ENT
Lead clamp (load) Not use Front Sensor [pulse] (Allowable range: -100 to 100) Perform the fine adjustment for the position check for plate leading edge when loading. (Adjust the position of the sensor so that the sensor turns from On to Off.) Tail clamp [pulse] (Allowable range: -100 to 100) Precisely adjusts the drum position at which the trailing edge clamps will hold a plate. Squeeze rollor [pulse] (Allowable range: -100 to 100) Precisely adjusts the drum position at which the squeeze roller will be lowered. Balancer pin Not use Pick up clamp [pulse] (Allowable range: -100 to 100) Precisely adjusts the drum position to the pick up clamp position. Tail clamp (unload) [pulse] (Allowable range: -100 to 100) Precisely adjusts the drum position at which the trailing edge clamps will be released from the drum. Length Sensor [pulse] (Allowable range: -100 to 100) Sets a value to correct the plate size in the primary scanning direction. Adjust the value in the screen accessed by the following order. (Select User Maintenance
D-52
→
RH
.)
PT-R4300 SERVICE MANUAL
D.Operation panel 3855
Press
Save Data ? YES
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-53
D.Operation panel 3-8-5.Punch Adjustment screen 3706
Punch adjust
Punch adjust
Allows you to set a correction value for positioning the punch unit with reference to a plate’s center, and
Calibration position Set punch data
adjusts the spring tension in the plate side alignment unit.
RH parameter Drum parameter ESC
OK
NEXT
Pressing the Punch adjust
key after selecting the key brings up the Punch AdjustOK
ment screen in which you can correct the punch position with reference to the plate center and adjust the tension of the spring in the plate side alignment unit. ESC
Returns you to the previous screen. 3860
CLR
Punch adjust
7
8
9
4
5
6
1
2
3
0
.
-
0.000 [mm] 0.000 [mm] 0.000 [mm]
ESC
ENT
SAVE
3865
YES
D-54
: Fine adjustment for the cam follower position at Home side sensor is performed. : Fine adjustment for the cam follower position at Away side sensor is performed.
Press
Save Data ?
ESC
: Coarse adjustment for the cam follower position is performed.
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-6.Calibration Sensor Position Adjustment screen 3706
Calibration position
Punch adjust
Set punch data
Allows you to input a correction value for the position of the calibration sensor.
RH parameter
Pressing the
Calibration position
Calibration position
Drum parameter ESC
OK
NEXT
key after selecting the key brings up the Calibration SenOK
sor Position Adjustment screen in which you can set a correction value for the position of the calibration sensor. ESC
Returns you to the previous screen. 3870
CLR
Calibration position
7
8
9
4
5
6
1
2
3
2.5 [mm]
0
ESC
· ENT
SAVE
3875
Save Data ? YES
ESC
NO
It is possible to simply input the correction value from this screen. However, to assure a more precise correction value, be sure to adjust the value following the procedure described in “3-7-6 Calibration Position screen”. SAVE
Allows you to save the new data. Press data.
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D-55
D.Operation panel 3-8-7.Punch Data Setting screen 3706
Set punch data
Punch adjust
Allows you to set parameters for optional punch units. OK Pressing the key after selecting the
Calibration position Set punch data
Set punch data
key brings up the Punch Data Setting screen in which you can set data for the optional
RH parameter Drum parameter ESC
OK
NEXT
punch units. ESC
Returns you to the previous screen. 3880 Block
Width
No.1
0
0
No.2
0
0
No.3
0
0
No.4
0
0
No.5
0
0
No.6
0
0
No.7
0
0
No.8
0
0
No.9
0
0
ESC
CLR
A
B
7
8
9
C
4
5
6
D
1
2
3
E
0
mounted on the machine. Entering a number for a punch unit position where no punch unit is mounted could cause an error during punch operation.
ENT
F
SAVE
·
Enter the punch unit position number (connector number) for the optional punch unit
Also input the punch pitch into the Set punch name field to simplify later settings of the punch unit name. SAVE
Allows you to save the new data. 3855
Press data.
Save Data ? YES
ESC
YES
and then
OK
If you want to cancel the save, press then OK .
NO
NO
and
OK
Home side
Away side
No.1 No.2 No.3 Registration punch
D-56
to save the setting
No.4 No.5 No.6 Registration punch
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-8.Recording Head Parameter Setting screens 3706
RH parameter
Punch adjust Calibration position Set punch data
Allows you to set parameters for the board and laser diodes in the RH unit.
RH parameter
Pressing the RH parameter
Drum parameter ESC
3895
OK
NEXT
Allows entry of the target laser power used for channel calibration at each resolution. (Refer to D-59)
Laser power confirm Reference laser power
Laser power adjust
Temperature setting OK
NEXT
setting RH parameters.
Laser power setting
Laser power setting Laser power adjust
ESC
key after selecting the key brings up the menu screen for OK
NEXT
NEXT
Allows precise adjustment of the power of each LD channel at each resolution. (Refer to D-60) Laser power confirm
Allows the checking of the electric current (Iop) used in a laser diode channel at each resolution and the output power values of Ip1, Ip2, and Ip3, which are specified in Laser power setting. (Refer to D-61) Reference laser power
Allows the checking of the rated output current (Iopd) at each resolution. (Refer to D-62) Temperature setting
Allows entry of the parameters for temperature in the RH unit. (Refer to D-63)
PT-R4300 SERVICE MANUAL
D-57
D.Operation panel 3896
Laser running time
Laser running time
Displays or clears the cumulative laser illumi-
Writing time clear
nation time. (Refer to D-64)
Board costant setting Auto calibration
Writing times clear
Set temp. warning ESC
OK
NEXT
Displays or clears the number of times that the laser illumination time data has been written to the EEPROM. (Refer to D-65) Board costant setting
Allows the checking of parameters that are unique to each board of recording head. (Refer to D-66) Auto calibration
Allows you to set the execution time for auto calibration. (Refer to D-69) Set temp. warning
Allows you to set the warning error level for temperature. (Refer to D-72)
D-58
PT-R4300 SERVICE MANUAL
D.Operation panel 1) Laser Power Setting screen 3895
Laser power setting
Laser power setting
Allows entry of the target laser power used for chan-
Laser power adjust
nel calibration at each resolution. OK key after selecting the Pressing the
Laser power confirm Reference laser power
Laser power setting
Temperature setting ESC
OK
NEXT
key brings up the Resolution Selec-
tion screen. ESC
Returns you to the previous screen. 3900
Resolution 1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
Select a resolution and then press the key.
OK
The Data Input screen appears. Input the target laser power for channel calibration and the power output percentage at each
OK
specified measurement point. Lpw value
3901
1200dpi : 240mw 2000dpi : 270mw
CLR Lpw
Ip1
Ip2
Ip3
270
90
75
50
LPW(original)
7
8
9
4
5
6
1
2
3
0
.
-
2400dpi : 240mw 4000dpi : 270mw
[mW] 270
ESC
2438dpi : 240mw 2540dpi : 230mw
ENT
SAVE
Ip1 value 90%(Fixed and applied to all resolutions.) Ip2 value 75%(Fixed and applied to all resolutions.) Ip3 value 50%(Fixed and applied to all resolutions.) ESC
Returns you to the previous screen. SAVE
Allows you to save the new data. Press
3905
Save Data ? YES
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-59
D.Operation panel 2) Laser Power Adjustment screen 3895
Laser power adjust
Laser power setting
Allows precise adjustment of the power of each LD
Laser power adjust
channel at each resolution. OK key after selecting the Pressing the
Laser power confirm Reference laser power
Laser power adjust
Temperature setting
key brings up the Resolution Selec-
tion screen. ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 3910
Resolution 1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
3911
Ch.0 Ch.1 Ch.2 Ch.3 Ch.4 Ch.5 Ch.6 Ch.7
Select a resolution and then press the key.
OK
The Data Input screen appears.
OK
A B 0 1.00 1.00 0 1.00 0 0 1.00 1.00 0 1.00 0 1.00 0 0 1.00
7
8
9
All the parameter setting values in this screen are
4
5
6
1
2
3
fixed. Therefore, be sure to never modify any of them.
0
OK
· ENT
A: 1.00 B: 0 SAVE
○
○
ESC
CLR
○
○
Allow you to save the new data.
3919
Save Data ? YES
ESC
D-60
NO
Press data.
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3) Laser Power Confirmation screen 3895
Laser power confirm
Laser power setting
Allows the checking of the power output of LD with
Laser power adjust
the value set in the Ip1, Ip2, and Ip3 fields in the Laser Power setting screen at each resolution.
Laser power confirm Reference laser power
Pressing the
Temperature setting
Laser power confirm
ESC
OK
NEXT
key after selecting the key brings up the Resolution SelecOK
tion screen. ESC
3920
Returns you to the upper layer Menu screen.
Resolution 1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
Select a resolution and then press the key. The Data confirmation screen appears. Iop: [mA] (Allowable range: 0 to 2000)
OK
Electric current required to obtain a light intensity of Lpw (target laser power used for channel
3921
CLR Iop Pw1 Pw2 Pw3 [mA] [mw] [mw] [mw] ch.0 ch.1 ch.2 ch.3
836 827 797 788
244 237 239 239
102 105 103 102
194 193 186 185
7
8
9
4
5
6
1
2
3
0
. ENT
OK
calibration) Pw1 : Power measured when an LD is lit using the electrical current value “lop” × “lp1”. Pw2 : Power measured when an LD is lit using the electrical current value “lop” × “lp2”. Pw3 : Power measured when an LD is lit using the electrical current value “lop” × “lp3”.
○
○
○
ESC
OK
○
Although it is possible to change the data settings for each LD channel in this screen, modifying any of them could adversely affect the resulting beam balance of the recording head. Therefore, never change the data setting in this screen. SAVE
Allows you to save the new data. 3929
Press
Save Data ? YES
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-61
D.Operation panel 4) Reference Laser Power Setting screen 3895
Reference laser power
Laser power setting
Allows the checking and entry of the rated output cur-
Laser power adjust
rent (Iopd) of the LD channels at each resolution. OK key after selecting the Pressing
Laser power confirm Reference laser power
ESC
key brings up the screen in which you can input parameter settings. Reference laser power
Temperature setting OK
NEXT
ESC
Returns you to the upper layer Menu screen. 3930
Select the resolution and press the OK key. The screen in which you can input parameter
Resolution 1200 dpi
2000 dpi
2400 dpi
4000 dpi
2438 dpi
2540 dpi
ESC
settings is displayed.
OK
3931
CLR
ch.0 ch.1 ch.2 ch.3
Iopd Imd Ithd [mA] [mA] [mA]
7
8
9
120 120 120 120
4
5
6
1
2
3
0
.
-
1107 1131 1119 1134
0.00 0.00 0.00 0.00
nel lmd : Fixed to 0.00. (NEVER change this setting.) lthd : Fixed to 120. (NEVER change this set-
ENT
OK
ting.)
○
○
ESC
lopd : (Allowable range : 0 to 2000) Maximum rated current for each LD chan-
○
○
SAVE
Allows you to save the new data. 3939
Save Data ? YES
ESC
D-62
NO
Press data.
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 5) Temperature Setting screen 3895
Temperature setting
Laser power setting
Allows entry of the parameter for the temperature in
Laser power adjust
the RH unit. Pressing the
Laser power confirm Reference laser power
key after selecting the
Temperature setting
Temperature setting ESC
OK
OK
NEXT
key brings up the Temperature Setting screen in which you can input parameter settings.
All the values appearing in this screen are fixed values. NEVER modify any of them. 3940
Temparature Pelter ctl. DAC 1.
255
3.
0
2.
255
Alarm leve LD
28
Env.
35
ESC
CLR
25
Fin
55
7
8
9
4
5
6
1
2
3
0
.
-
ENT
SAVE
Temperature: The control temperature of the Peltier element has been set. Alarm level : The temperatures at which an error will occur during temperature checks (of the following items) have been set. LD : Temperature of the laser diodes. Fin : Temperature of the Peltier element’s cooling fan. Env. : Temperature of the periphery of the RH unit. SAVE
Allows you to save the new data. 3945
Press
Save Data ? YES
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-63
D.Operation panel 6) Laser Illumination Time screen 3896
Laser running time
Laser running time
Displays or clears the cumulative laser illumination
Writing time clear
time. Pressing the
Board costant setting Auto calibration
OK
key after selecting the
key brings up the Laser Illumination Time Display/Clear screen. Laser running time
Set temp. warning ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 3950
0. 1. 2. 3. 4. 5. 6. 7.
123 123 123 123 123 123 123 123
8. 9. 10. 11. 12. 13. 14. 15.
ESC
123 123 123 123 123 123 123 123
16. 17. 18. 19. 20. 21. 22. 23.
123 123 123 123 123 123 123 123
SAVE
24. 25. 26. 27. 28. 29. 30. 31.
[Hour] 123 123 123 123 123 123 123 123
CLEAR
Displays the screen in which you can clear the laser illumination time.
CLEAR
Input the number of the ID channel whose illumination time you want to clear, and then press
3951
CLR
LD No. (0-31 32 : ALL) 32
ESC
7
8
9
4
5
6
1
2
3
0
.
START
ENT
the
ENT
key.
0-31 : Clears the laser illumination time for only the 32
selected LD channel. : Clears the laser illumination time for all the LD channels. Then, press the START key. The Laser Illumination Time Clear screen appears.
3956
Pressing the OK key clears the specified laser illumination time. CANCEL
Data Clear ?
The Laser Illumination Time Display/Clear screen reappears.
ESC
D-64
OK
CANCEL
PT-R4300 SERVICE MANUAL
D.Operation panel 7) EEPROM Write Count Clear screen 3896
Writing times clear
Laser running time Writing time clear
Displays or clears the number of times that the laser
Board costant setting
illumination time data has been written to the EEPROM.
Auto calibration Set temp. warning ESC
OK
NEXT
(The number of times that the laser illumination time has been written to the EEPROM, equivalent to the image exposure count, is displayed.) OK Pressing the key after selecting the Writing times clear
key brings up the EEPROM Write Count Clear screen. ESC
Returns you to the previous screen. 3960
CLEAR
Brings up the screen in which you can clear the
Writing time
EEPROM write count. Pressing the OK key clears the EEPROM
1729
ESC
write count. On command completion, the upper layer menu screen reappears.
CLEAR
3965
ESC CANCEL
Data Clear ?
ESC
OK
Returns you to the previous screen.
CANCEL
PT-R4300 SERVICE MANUAL
D-65
D.Operation panel 8) Recording Head Board Parameter Input screen 3896
Board costant setting
Laser running time
Allows entry of parameters that must be set for an individual board when it is replaced.
Writing time clear Board costant setting
Pressing the
Auto calibration
Board costant setting
Set temp. warning
key after selecting the key brings up the Recording Head OK
Board Parameter Input screen. ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. Parameters that are set in this menu are unique values for each CPU and driver board of the recording head. Always set these parameter values whenever replacing these boards. 3970
CPU Board Temparature sensor Tm1 Tm2 50C 19.4 30.0 100C 30.2 59.5
Dew condensation sensor R1 10 R2 101 Calibration sensor Cal1 488 Cal2 3965
ESC
OK
CLR 7
8
9
4
5
6
1
2
3
0
.
-
ENT
Parameters of CPU board for recording head Temperature sensor 50C : Corrects the input/output differences occurring in the board’s circuitry when receiving input from the temperature sensors provided for the LD base and machine interior. Tm1: 20ºC Tm2: 30ºC 100C : Corrects the input/output differences occurring in the board’s circuitry when receiving input from the temperature sensors provided for the Peltier fan. Tm1: 30ºC Tm2: 60ºC Dew condensation sensor Corrects the input/output differences occurring in the board’s circuitry when receiving input from the dew condensation sensors. R1: 10 kW R2: 100 kW
D-66
PT-R4300 SERVICE MANUAL
D.Operation panel 3971
CLR Cal. Sensor Gain
7
8
9
7759
4
5
6
1
2
3
0
.
ESC
Corrects the input/output differences occurring in the board’s circuitry when receiving input from calibration sensors. Cal1: 500 mV Cal2: 4000 mV Cal. Sensor Gain
ENT
OK
Calibration sensor
Displays the Gain value attached to the calibration sensor board. 3972
Driver Board 1
CLR
Im1[mA] Im2[mA]
ch.26 ch.19 ch.12 ch. 5 ch. 6 ch.13 ch.20 ch.27
235 267 265 242 251 261 242 251
ESC
3973
949 966 993 969 982 994 966 970
7
8
9
4
5
6
1
2
3
0
.
Driver Board 2 248 264 235 246 258 251 238 256
ESC
3974
969 986 955 970 972 971 971 973
7
8
9
4
5
6
1
2
3
0
. ENT
OK
Driver Board 3 243 239 251 263 237 262 254 272
ESC
3975
960 957 974 988 958 979 977 1001
CLR 7
8
9
4
5
6
1
2
3
0
. ENT
OK
Driver Board 4
CLR
Im1[mA] Im2[mA]
ch.24 ch.17 ch.10 ch. 3 ch. 4 ch.11 ch.18 ch.25
ESC
254 249 243 254 258 257 249 258
968 971 966 967 978 958 975 968
SAVE
in the driver board’s circuitry when outputting current to run the LD.
CLR
Im1[mA] Im2[mA]
ch. 8 ch. 1 ch.30 ch.23 ch.16 ch. 9 ch. 2 ch.31
Im1, Im2 Corrects the input/output differences occurring
ENT
OK
Im1[mA] Im2[mA]
ch.28 ch.21 ch.14 ch. 7 ch. 0 ch.15 ch.22 ch.29
Parameters of driver board for recording head
7
8
9
4
5
6
1
2
3
0
. ENT
PT-R4300 SERVICE MANUAL
D-67
D.Operation panel 3999
Press
Save Data ? YES
ESC
D-68
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 9) Auto Calibration setting screen 3896
Auto calibration
Laser running time
Allows you to set the time for auto calibration and the
Writing time clear
temperature at which an error warning will occur. OK key after selecting the Pressing
Board costant setting Auto calibration
Auto calibration
Set temp. warning ESC
OK
NEXT
key brings up the setting screen for auto calibration time and the error warning levels. ESC
Returns you to the upper level Menu screen. 3980
CLR
Auto calibration
7
8
9
2405
Meas. thd(%) Cal. period (Hour)
10
4
5
6
Iopd-Iop
50
1
2
3
Cal. low temp
16
0
.
ESC
OK
ENT
Meas. thd (%) (Allowable range: 0 to 9999) Default setting value is 2405. Former two digits Sets the number of plates to process before the light intensity is measured. Default setting value is 24 plates. Latter two digits Sets the allowable range in % for the measured value of light intensity. If the measured value falls out of this range, a calibration is performed. Default setting value is 5%. Cal. period (Hour) (Allowable range: -60 to 999) Once the exposure is performed for the period specified in this parameter, a calibration is automatically performed. A negative value indicates minutes while a positive value indicates hours. When “0” is set here, calibration is not performed. When “-1”, “-2”, or “-3” is set here, calibration is executed before each time an exposure is performed. Default setting value is 10 hours. Iopd - Iop (Allowable range: 0 to 100) A warning message appears on screen when the value obtained by calculating the following formula is smaller than the value that was specified in this parameter when performing the calibration. Iopd - Iop Default setting value is 50 mA.
PT-R4300 SERVICE MANUAL
D-69
D.Operation panel Cal. low temp (Allowable range: 0 to 300) The calibration is prohibited when the temperature for an LD block is lower than the temperature specified in this parameter. Default setting value is 16 °C. 3971
Press
Save Data ? YES
ESC
D-70
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D.Operation panel Auto calibration The following describes the detailed operations of the items that are shown in the tables. Light intensity measurement: Measures light intensity of all channels. If the measured value deviates from the target light intensity, it performs a calibration of the channel. Laser calibration: Changes the electric current supplied to channels to match the light intensity of the channels with the target light intensity. Panel message displayed Calibration condi- Channel to be when performing calibration calibrated tions xx plates ago. After PT-R8600 Light intensity When light inten- All channels Since the light intensity of lapower is turned ON measurement sity for any channel ser diodes is detected as havfalls out of range of ing deviated more than the and before the first the target value ± permitted range from the plate exposure 5% specified value, the equipment executes the calibration. After exposure of Light intensity When light inten- All channels xx plates ago. 24th plate and be- measurement sity for any channel Since the light intensity of lafalls out of range of ser diodes is detected as havfore exposure of the the target value ± ing deviated more than the next plate 5% permitted range from the specified value, the equipment executes the calibration. After 10 hours of Laser calibraAll channels No message displayed exposure time has tion elapsed and before – exposure of the next plate All channels No message displayed When the resolution Laser calibrahas been changed tion (when calibration has been performed – with another resolution before the present resolution was changed) Operations
PT-R4300 SERVICE MANUAL
D-71
D.Operation panel 10) Temperature Warning and Error Level Setting screen 3896
Laser running time
Set temp. warning
Allows setting of the temperature warnings and error
Writing time clear
levels. Pressing the
Board costant setting Auto calibration
OK
key after selecting the
key brings up the screen in which you can set the temperature warnings and error levels. Set temp. warning
Set temp. warning ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4140
CLR
Set temp. 2 (35) (28) (22) (16) (17) --Grip After-Grip
35 28 22 16 17 28 150 128
ESC
7
8
9
4
5
6
1
2
3
0
. ENT
OK
This section varies depending on the PT-R4000II and the PT-R4300.
Do not change the parameters of (##) displayed in this screen. These parameters are used when switching error displays that are related to temperatures. (35) : Temperature around recording head (28) : Temperature in the PT-R unit (22) : LD base temperature (18) : Temperature in the PT-R unit (16) : LD base temperature Password/--- : PT-R4000 (II) Password : Input the password when the 12 mm clamps are supported. PT-R4300 Password : Not used Grip: (Allowable range: 110 to 999) After-Grip : (Allowable range: 110 to 999) Adjusts the unexposed area of leading grip margin (Grip) and trailing grip margin (AfterGrip). • When input value is 120 to 999 Sets the unexposed area. Input an appropriate size, 1 enlarges the area by 0.1 mm.
4145
For the PT-R4000 and PT-R4000II (up to Ver.
Save Data ? YES
ESC
D-72
NO
OK
4.00), the lower limit value of the input range is 140. Press data.
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-9. Drum Parameters Input screen 3706
Drum parameter
Punch adjust
Set punch data
Allows setting of the parameters for the drum motor driver.
RH parameter
Pressing the
Calibration position
Drum parameter
Drum parameter ESC
4005
OK
Parameter set Status read Initialize Adjust Offset Adjust Gain
ESC
OK
NEXT
key after selecting the key brings up the menu screen for OK
the drum parameter.
Parameter set
Allows the checking of the servo pack parameter value. (for PT-R4300 only) (Refer to D-74) Status read
Displays the status of the servo pack. (Refer to D-75) Initialize
Sends the default parameters of the servo pack to the servo pack. (Refer to D-77) Adjust Offset
Adjusts the Offset value for the servo pack. (Refer to D-78) Adjust Gain
Adjusts the Gain value for the servo pack. (Refer to D-79)
PT-R4300 SERVICE MANUAL
D-73
D.Operation panel 1) Servo Pack Parameter Check screen • For PT-R4000 (II) 4005
Parameter set
Parameter set
Status read
Not used. Allows checking of the servo pack parameter value. OK key after selecting the Pressing the
Initialize Adjust Offset
Parameter set
key brings up the servo pack parameter check screen.
Adjust Gain ESC
OK
ESC
Returns you to the upper layer Menu screen. The screen shown on the left is displayed. However, you are not allowed to change the pa-
4010
A
CLR
B
7
8
9
C
4
5
6
D
1
2
3
E
0
rameter setting. CN-
ESC
4
• ENT
F
OK
• For PT-R4300 4010
Positioning Pn100
15
Pn101
25
Pn103 3000 Pn100
300
CLR 7
8
9
4
5
6
1
2
3
0
.
The screen shown on the left includes the parameters relevant to the operation of the primary-scanning motor.
Pn101 4000 Pn103
100 0 0
ESC
ENT
OK
Do not change these parameter values as they are fixed.
4015
Save Data ? YES
ESC
D-74
NO
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 2) Servo Pack Status screen 4005
Status read
Parameter set
Allows displaying of the status of the servo pack.
Status read
Pressing the
Initialize
Status read
Adjust Offset
screen.
Adjust Gain ESC
key after selecting the key brings up the servo pack status OK
ESC
OK
Returns you to the upper layer Menu screen. 4020
Sarvo pack status 0804 0808 080A 080C 0820 0822 0840 0842
0099 0844 0014 0846 00C1 0848 BC6B 084A 0000 084C 0000 084E 0099 0850 0080 0852
0099 0099 0099 0099 0099 0099 0099 0099
850A 8500 to 8509
: Current status : History of the primary-
scanning servo pack status Other than above : Unique parameter values for the servo pack
ESC
Indication 02 03 04 05 10 30 32 40 41 51 71 72
73 74 7A 81 82 83 84 85
Name Parameter corruption Main circuit’s detection section error Parameter setting error Compatibility error Overcurrent or heat sink overheat
Description There is an error in the EEPROM data for the servo pack. There is an error in the detection data of the power circuit. The value set by the user is out of the allowable range. The capacity of the motor is incompatible with that of the servo pack. Overcurrent was detected or the heat sink of the servo pack was overheated.
The regenerative resistance was disconnected or the regenerative transistor was damaged. The regenerative energy exceeds the capacity Regenerative overload of the regenerative resistance. The DC voltage of the main circuit is abnorOvervoltage mally high. The DC voltage of the main circuit has been Undervoltage lowered. The number or rotation of the motor is abnorOverspeed mally high. The operation was carried out for some secOverload (instantaneous onds at a torque that exceeded the rated value maximum load) significantly. Overload (continuous max- The operation was carried out continuously at a torque that exceeded the rated value signifiimum load) cantly. The rotational energy of the dynamic brake Overload of DB operation exceeded the capacity of the dynamic brake resistance value. The power supply to the main circuit was Overload of incoming turned ON/OFF frequently. resistance The heat sink of the servo pack was Heat sink overheat overheated. The encoder power supplies were deactivated Encoder backup alarm entirely and the position data was cleared. Encoder sum check alarm There is an error in the result of the encoder memory sum check. The voltage for the backup battery of the Encoder battery alarm absolute value encoder has been lowered. There is an error in the encoder internal data. Encoder data alarm Regenerative error
Encoder overspeed
PT-R4300 SERVICE MANUAL
The encoder rotated at a high speed when the power was turned ON.
Remedy Replace the servo pack. Replace the servo pack. Initialize or replace the servo pack. Replace the servo pack, the regenerative resistance, and/or the motor. Check the wiring connection, check the peripheral temperature, replace the servo pack, and/or replace the motor. Replace the servo pack and/or regenerative resistance. Initialize the servo pack or replace the regenerative resistance. Check the input voltage and/or replace the servo pack. Check the input voltage and/or replace the servo pack. Check the wiring connection, initialize the servo pack, and/or replace the servo pack. Check the wiring connection, replace the motor, and/or replace the servo pack. Same as above Replace the servo pack. Replace the servo pack. Check the peripheral temperature and/or replace the servo pack. Initialize the servo pack, replace the motor, and/or replace the servo pack. Initialize the servo pack, replace the motor, and/or replace the servo pack. Initialize the servo pack and/or replace the motor. Check the wiring connection and/or replace the servo motor. Check whether the recording drum is rotating and/or replace the servo pack.
D-75
D.Operation panel Indication 86 b1 b2 bF C1 C8 C9 CA Cb CC d0 F1
D-76
Name Encoder overheat Speed command A/D converter error Torque command A/D converter error System alarm Detection of runaway protection Encoder clear error/multiturn limit setting error Encoder communication error Encoder parameter error Encoder echo back error Disagreement of the multiturn limit value Excessive positional deviation Open-phase of the power supply line
Description The motor temperature in the encoder is too high. (This is detected only when the absolute value encoder is used.) There is an error in the A/D converter for inputting the speed command. There is an error in the A/D converter for inputting the torque command. A servo pack system error occurred. The servo motor ran away. The number of rotations for the multi-turn setting of the absolute value encoder could not be cleared or set correctly. The communication between the encoder and the servo pack cannot be established. An encoder parameter has been corrupted. The communication with the encoder is inaccurate. The multi-turn limit values of the encoder and the servo pack disagree. The positional deviation pulse exceeded the user set value. One of the three phases for the power supply of the main circuit is disconnected.
Remedy Check the peripheral temperature, replace the servo pack, and/or replace the servo motor. Replace the servo pack. Replace the servo pack. Replace the servo pack. Check the wiring connection, replace the servo pack, and/or replace the motor. Replace the motor and/or replace the servo pack. Check the wiring connection, replace the motor, and/or replace the servo pack. Replace the servo pack and/or replace the motor. Check the wiring connection, replace the motor, and/or replace the servo pack. Initialize the servo pack. Check the wiring connection, initialize the servo pack, and/or replace the servo pack. Check the wiring connection and/or replace the servo pack.
PT-R4300 SERVICE MANUAL
D.Operation panel 3) Servo Pack Initialization screen 4005
Parameter set Status read
Allows sending of the default parameters of the servo
Initialize
pack to the servo pack. OK key after selecting the Pressing the
Adjust Offset Adjust Gain ESC
Initialize
OK
key sends the default parameters of the servo pack to the servo pack. Initialize
ESC
4030
Send initial parameter
Returns you to the upper layer Menu screen.
Data send OK ?
ESC
OK
PT-R4300 SERVICE MANUAL
D-77
D.Operation panel 4) Servo Pack Offset Adjustment screen 4005
Parameter set Status read Initialize Adjust Offset Adjust Gain
ESC
OK
Adjust Offset
Allows adjusting of the Offset value for the servo pack. Pressing the
OK
key after selecting the
Adjust Offset
key brings up the servo pack Offset value adjustment screen.
Make sure to perform this procedure when replacing the motor, servo pack, and PIO. ESC
Returns you to the upper layer Menu screen. It takes approximately 20 seconds until the
2262
screen shown on the left is displayed. After the adjustment has been completed, the Processing Now. Please wait !
D-78
Menu screen is displayed.
PT-R4300 SERVICE MANUAL
D.Operation panel 5) Servo Pack Gain Adjustment screen 4005
Parameter set Status read Initialize Adjust Offset Adjust Gain
ESC
Adjust Gain
Allows adjusting of the Gain value for the servo pack. Pressing the Adjust Gain
key after selecting the key brings up the servo pack Gain OK
value adjustment screen.
OK
Be sure to check the Gain value whenever you replace the motor, the servo pack, or the PIO board.
When performing the above procedure, be careful as the recording drum will rotate. ESC
Returns you to the upper layer Menu screen. It will take about 20 seconds before the screen on
4050
Adjust Gain Offset : A5 +
the left appears. Use the POI board trimmer to adjust the value to “A0 ± 8”. The adjustment value is common to the PT-
ESC
PT-R4300 SERVICE MANUAL
R4000 and the PT-R4300.
D-79
D.Operation panel 3-8-10.Miscellaneous Data Setting screen 3707
Set misc. data
Set misc. data
Displays miscellaneous machine information including the manufacturing number of the machine.
Set resolution
Set weight
Pressing the
Set cassette data
Set misc. data
Password for spec. func
ESC
OK
NEXT
key after selecting the key brings up the data input screen OK
for miscellaneous machine information including the manufacturing number of the machine. ESC
Returns you to the upper layer Menu screen. 4100
CLR Mfg.no(high):
0
Mfg.no(low):
600
Mfg.year:
2
Mfg.month:
5
Machine type 2:
0
Machine type :
2
ESC
7
8
9
4
5
6
1
2
3
0
. ENT
SAVE
Machine Type 2: Default setting value: 0 “0” Normal operation with the main unit firmware as mentioned below. “4” Disconnection of image signal cables (X103 X810) between the RB31 board and the recording head is checked (refer to “3-7-9 Laser Power Measurement and Cable Disconnection Check screens”) only with the following firmware versions. PT-R4000 : Ver. 3.06 or higher PT-R4000II : Ver. 4.04 or higher PT-R4300 : Ver. 1.00 or higher Machine Type: The serial numbers (s/n) mentioned below are common to the PT-R4000 (II) and the PTR4300. “0” When the black tape for the displacement sensor is not affixed to the drum. (s/n: up to 100) “2” When the black tape for the displacement sensor is affixed to the drum. (s/n: 101 onward)
4105
Save Data ? YES
ESC
D-80
NO
Press data.
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-11.Recording Head Data Control screen Set resolution
3707
Set misc. data
Allows controlling of the data for each resolution used by the recording head.
Set resolution
Set weight
Pressing the
Set cassette data
Set resolution
Password for spec. func
key after selecting the key brings up the recording head OK
data control screen. ESC
OK
NEXT
Do not change any of the data. 4120
CLR
Set density dpi ZP 2 1 2 3 2 4
1200 2000 2400 4000 2438 2540
ESC
7
8
9
4
5
6
1
2
3
0
.
Returns you to the upper layer Menu screen.
ENT
SAVE
4125
Press
Save Data ? YES
ESC
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-81
D.Operation panel 3-8-12.Clamp Weight Setting screen Set weight
3707
Set misc. data
Allows inputting of the weights of the trailing edge clamps and the balancers.
Set resolution
Set weight
Pressing the
Set cassette data
Set weight
Password for spec. func
ESC
OK
NEXT
key after selecting the key brings up the screen in which OK
you can input the weights of the trailing edge clamps and the balancers. ESC
Returns you to the upper layer Menu screen. 4130
CLR
Clamper:
381.89[g]
Balancer:
165.00[g]
ESC
7
8
9
4
5
6
1
2
3
0
.
Balancer [g] (Allowable range: 0.00 to 999.99) Input the average weight of four balancers.
Press data.
Save Data ? YES
D-82
Input the total weight of four trailing edge clamps.
ENT
SAVE
4135
ESC
Clamper [g] (Allowable range: 0.00 to 999.99)
NO
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-8-13.Cassette Data Setting screen Set cassette data
3707
Set misc. data
Allows the setting of the plate size to be used for each cassette zone.
Set resolution
Set weight
Pressing the
Set cassette data
Set cassette data
Password for spec. func
key after selecting the key brings up the screen in which OK
you can set the plate size for each cassette zone. ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4140
CLR
Set cassette data [mm] Paper pad suk Paper pad nip Y size base A Y size base B Y size base C Zone-2 min. size Zone-3 min. size Zone-4 min. size
ESC
10 190 0 9808 478 460 610 730
NEXT
7
8
9
4
5
6
1
2
3
0
. ENT
Paper pad suck [0.1 mm] (Allowable range: -20 to 20) The interleaf pad position for securing interleaves is corrected. The reference point is where the metal sensor of the interleaf pad turns ON. Paper pad nip [0.1 mm]: Positional relationship between the interleaf pad and the nip roller while an interleaf is discharged is corrected. Set the distance from the interleaf pad origin. Y size base A, B, C: The plate size in the Y (primary scanning) direction is checked while the plate is transferred from the SA-L/MA-L in reference to the value specified for this parameter.
The values of these parameters must be set again in case of the following conditions. • The nip roller used at the bridge section of the SA-L/MA-L has been replaced. • The distance between sensor 1 and sensor 2 of the SA-L/MA-L has been changed. • The sensor 1 amplifier trimmer of the SA-L/MAL has been turned. Zone 2 min. size: Minimum size for zone area 2 Zone 3 min. size: Minimum size for zone area 3 Zone 4 min. size: Minimum size for zone area 4 PT-R4300 SERVICE MANUAL
D-83
D.Operation panel 4141
CLR
Set cassette data [mm] 0 0 0 0 0 0 0 0
motion Para1 ----------------------
ESC
SAVE
7
8
9
4
5
6
1
2
3
0
. ENT
The screen shown on the left is displayed when the firmware of the main unit is as below. PT-R4000 : Ver. 3.06 or higher PT-R4000II : Ver. 4.04 or higher PT-R4300 : Ver. 1.00 or higher motion para 1 (Allowable range: 0 to 9999) Sets an operation when returning the plate pad. Default setting value is 0. Each digit of the parameter value has meaning. 1 0 3 9 ABCD A [10%] (Allowable range: 0 to 9) Increases the amount by percentage of the first raising of the plate pad that has picked up a plate. During the operation, the plate pad is first raised and lowered slightly. The “first raising” however, refers to the operation that follows this movement. Default setting value is 0. The plate pad is raised by 50 mm. Example: When “1” is set, the plate pad unit is raised 10% more than the default (50 mm). B [10%] (Allowable range: 0 to 9) Increases by percentage the distance that the plate pad is lowered from the A position in order to shuffle the plate. Default setting value is 0. Default distance • When the plate size in the X direction is less than 600 mm or the plate thickness is 0.15 mm: 10 mm • Other cases than above: 25 mm The distance that the plate is to be moved varies with the plate size and thickness. Once this value is changed, a variety of checks are required. We recommend that you use the default value. Example (plate thickness: 0.15 mm): When “1” is set, the plate pad unit is lowered 10% more than the default (10 mm).
D-84
PT-R4300 SERVICE MANUAL
D.Operation panel C [sec.] (Allowable range: 0 to 9) Waiting time at the A position until the B operation starts. This sets the waiting time of the plate pad at its first raised position. Default setting value is 0. Example: When “3” is set, the plate pad pauses for 3 seconds. D [sec.] (Allowable range: 0 to 9) Additional increment to the waiting time between when the shuffling operation has been performed four times consecutively and when the plate is raised again. This sets the waiting time of the plate pad at the A position after the plate has been shuffled between A and B four times. Default setting value is 0. The plate pad waits for 4 seconds. Example: When “9” is set, 9 seconds are added to the default of 4 seconds. As of April 2002, we recommend that you should set “motion para 1” to “1039” when handling the interleaves for the new type of “LT-2/3” plate made by Mitsubishi Chemical Corporation. 4145
Press
Save Data ? YES
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-85
D.Operation panel 3-8-14.Password Setting screen 3707
Password for spec. func
Set misc. data
Allows setting of the password for various special functions.
Set resolution
Set weight
Pressing the
Set cassette data
Password for spec. func
Password for spec. func
ESC
OK
NEXT
key after selecting the key brings up the screen in which OK
you can set the passwords to support various special functions. ESC
Returns you to the upper layer Menu screen. Password 1 : Not used.
3850
CLR
Password for s Password Password Password Password Password Password Password Password
ESC
0 0 0 0 0 0 0 0
1 2 3 4 5 6 7 8
7
8
9
4
5
6
1
2
3
0
• ENT
SAVE
Password 2 : Not used. Password 3 : Not used. Password 4 : Not used. Password 5 : Not used. Password 6 : Not used. Password 7 : Not used. Password 8 : Not used. Press
3855
Save Data ? YES
ESC
D-86
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-9.Machine Option Selecting screen 3051
Machine option select
Input parameter
Allows setting of the options for the PT-R. OK key after selecting the Pressing the
Machine option select I/O Read/Write
Machine option select
key brings up the screen in which you can set options for the PT-R.
Initialize data Special action ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4203 Network
OFF
LD/Stocker
OFF
CASSETTE
OFF
Valid LD channel
32ch
ESC
Network Turned ON when remote maintenance is used. LD/Stocker LD
: It is possible to discharge plates to the processor (rear discharge). The Error and Busy signals are used for communication. Be sure to select “LD” when the
SAVE
Stocker
AT-T is connected. : Although it is possible to discharge plates to the processor (rear discharge), the Error and Busy signals
OFF
are ignored. : Plates are discharged within the machine. The rear discharge is not available.
CASSETTE OFF
: Select when the PT-R is used alone.
Single Multi
: Select when the SA-L is connected. : Select when the MA-L (three cassettes) is connected.
Valid LD channel
4205
Save Data ? YES
NO
32ch 0-15
: All channels are used for exposure. : Half of the LD channels (channels 0
16-31
to 15) are used for exposure. : Half of the LD channels (channels 16 to 31) are used for exposure.
ESC
OK
PT-R4300 SERVICE MANUAL
D-87
D.Operation panel 3-10.I/O Reading and Writing screen 3051
Input parameter
I/O Read/Write
Allows reading or writing of the I/O port number. OK key after selecting the Pressing the
Machine option select I/O Read/Write
I/O Read/Write
Initialize data
screen.
Special action ESC
OK
key brings up the port number input
NEXT
ESC
Returns you to the upper layer Menu screen. Input the port number to read and write the pa-
4300
I / O Port
READ
ESC
D-88
rameters of the PT-R.
WRITE
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-11.Initialization screens 3051
Input parameter
Initialize data
Allows initializing of various data. OK key after selecting the Pressing the
Machine option select I/O Read/Write
Initialize data
Initialize data
data initialization.
Special action ESC
4400
OK
NEXT
Initialize all data
Initialize all data
Select brand Initialize user data
Initializes all data. (Refer to D-90)
Consumable Timer
Select brand
Initialize preset media ESC
key brings up the menu screens for
OK
NEXT
Allows selection of the brand name. (Refer to D-91) Initialize user data
Only initializes the user data. (Refer to D-90) Consumable Timer
Initializes the Consumables Timer. (Refer to D-92) Initialize preset media
Initializes the preset plate data. (Refer to D-90)
PT-R4300 SERVICE MANUAL
D-89
D.Operation panel 3-11-1.Data initialization 4400
Initialize all data
Initialize data
Allows initializing of all data.
Select brand Initialize user data
Initialize user data
Consumable Timer
Allows initializing of only the user data.
Initialize preset media ESC
OK
NEXT
Initialize data ? Yes
D-90
Allows initializing of the preset plate data.
When initialization is performed using any of the
4402
ESC
Initialize preset media
above keys, all selected data will be cleared.
No
OK
PT-R4300 SERVICE MANUAL
D.Operation panel 3-11-2.Brand Name Selection screen 4400
Select brand
Initialize all data Select brand
Allows selecting of the brand name. OK Pressing the key after selecting the
Initialize user data
Select brand
Consumable Timer
lection screen.
Initialize preset media ESC
OK
key brings up the brand name se-
NEXT
ESC
Returns you to the upper layer Menu screen. 4401
Press the
SCREEN FUJIFILM
SAVE
key after selecting the brand
name.
HEIDELBERG HEIDELBERG(52)
ESC
SAVE
4402
Initialize data ? Yes
ESC
No
Press data.
YES
and then
OK
to save the setting
If you want to cancel the save, press then OK .
NO
and
OK
PT-R4300 SERVICE MANUAL
D-91
D.Operation panel 3-11-3.Consumable Timer screen 4400
Consumable Timer
Initialize all data
Allows initializing of the Consumable Timer. P r e s s i n g t h e OK key after selecting the
Select brand Initialize user data
Consumable Timer
key brings up the Consumable Timer initialization screens.
Consumable Timer Initialize preset media ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. Running time :
2240
Running time
Displays the total time the PT-R power is ON. Actual running time :
78 h Actual running time 21 h Exposure time
Displays the cumulative amount of time that the PT-R4300 has actually run.
10 h Plate winding cycles 215 ESC
SAVE
NEXT
Exposure time : Displays the cumulative amount of time that the exposure has been carried out. Plate winding cycles : Displays the number of plate loading cycles. Exterior cover filter :
2241
Exterior cover filter (Max:1000h) 78 h Clamp cycles 786 Plate winding cycles/ye 786
ESC
SAVE
RESET RESET RESET
NEXT
Initializes the cumulative amount of time that the exterior cover filter has been used. Clamp cycles : Initializes the number of cycles that the trailing edge clamps are detached from and attached to the clamp arm. Plate winding cycles/ye : Initializes the number of plate loading cycles in the past year. Punch cycles No.1-8 :
2242
D-92
Punch cycles (Max:10000) Punch cycles (Max:10000) Punch cycles (Max:10000) Punch cycles (Max:10000)
No.1
ESC
SAVE
78 No.2 78 No.3
RESET RESET
78
RESET
78
RESET
Initializes the number of times that the punch operates for each punch.
No.4
NEXT
PT-R4300 SERVICE MANUAL
D.Operation panel Press
2245
Save Data ? YES
ESC
NO
YES
and then
OK
to save the setting
data. If you want to cancel the save, press then
OK
NO
and
.
OK
PT-R4300 SERVICE MANUAL
D-93
D.Operation panel 3-12.Special Action screen 3051
Special action
Input parameter
Allows executing of some special operations such as trailing edge clamp attachment and status initializa-
Machine option select I/O Read/Write
tion. Pressing the
Initialize data Special action
Special action
ESC
OK
NEXT
OK
key after selecting the
key brings up the special action
screens. 4450
Initialize
Initialize
Initializes the PT-R. (Refer to D-95)
Initialize machine status Pick up clamp
Initialize machine status
Initializes the status of the PT-R. (Refer to D-95)
Check ORG-EZ
Pick up clamp
Put clamp on drum
ESC
OK
NEXT
Picks up the trailing edge clamps. (Refer to D-96) Check ORG-EZ
NEXT
NEXT
Not used. (Refer to D-97) Put clamp on drum
Attaches the trailing edge clamps to the drum. (Refer to D-96) 4451
Front sensor offset
Front sensor offset
Adjusts the positioning offsets at the Home and Away sides for the plate leading edge detection
Centering test Adjust Displacement sensor
ESC
NVRAM backup
sensors automatically. (Refer to D-98)
NVRAM restore
Centering test
OK
NEXT
NEXT
NEXT
Allows you to perform the centering operation. (Refer to D-99) Adjust displacement sensor
Adjusts the positioning install the displacement sensor. (Refer to D-100)
4452
Register test
NVRAM backup
Backs up the NVRAM data in the flash memory. (Refer to D-101) NVRAM restore ESC
OK
NEXT
Restores the NVRAM data from the flash memory. (Refer to D-102) Register test
Adjusts the positioning offsets at the Home and Away sides for the plate leading edge detection sensors automatically. (Refer to D-103) D-94
PT-R4300 SERVICE MANUAL
D.Operation panel 3-12-1.Machine Initialization screen 4450
Initialize
Initialize Initialize machine status Pick up clamp
Allows initializing of the PT-R. Initialize machine status
Allows initializing of the status of the PT-R.
Check ORG-EZ Put clamp on drum
ESC
NEXT
OK
4451
OK
Executes the initialization of the PT-R and of
Start OK ?
its status. Once the initialization has been completed, the upper layer Menu screen will appear.
ESC
OK
CANCEL
PT-R4300 SERVICE MANUAL
D-95
D.Operation panel 3-12-2.Pickup Clamp, Trailing Edge Clamp Attachment screen Pick up clamp
4450
Initialize Initialize machine status
Put clamp on drum
Pick up clamp
Allows attaching of the trailing edge clamps onto the drum.
Check ORG-EZ Put clamp on drum
ESC
OK
Allows picking up of the trailing edge clamps.
NEXT
This command should be used when the trailing edge clamps need to be taken out from the clamp arm for cleaning.
4451
OK
Executes the pickup of the trailing edge clamps
Start OK ?
ESC
D-96
OK
or the “Put clamp on drum” operation. Once the initialization has been completed, the upper
CANCEL
layer Menu screen will appear. When a plate is discharged, secure the drum at the position where the leading edge clamps open and then execute “Put clamp on drum”.
PT-R4300 SERVICE MANUAL
D.Operation panel 3-12-3.ORG-EZ Check screen 4450
Check ORG-EZ
Initialize Initialize machine status
Not used.
Pick up clamp Check ORG-EZ Put clamp on drum
ESC
NEXT
OK
4451
Start OK ?
ESC
OK
CANCEL
PT-R4300 SERVICE MANUAL
D-97
D.Operation panel 3-12-4.Front Sensor Offset screen 4451
Front sensor offset
Front sensor offset
Adjusts the positioning offsets at Home and Away sides for the plate leading edge detection sensors au-
Centering test Adjust Displacement sensor
tomatically. For the adjustment method, refer to page B-60.
NVRAM backup NVRAM restore
ESC
OK
NEXT
Pressing the Front sensor offset
Press the OK key after selecting the plate type and the screen for execution confirmation appears.
1050
1
Plate 1
2
Plate 2
3
Plate 3
4
Plate 4
5
Plate 5
ESC
OK
NEXT
4451
OK
Executes the automatic adjustment of the posi-
Start OK ?
ESC
key after selecting the key brings up the plate type screen. OK
OK
tioning offsets at Home and Away sides for the plate leading edge detection sensors.
CANCEL
The screen during the operation is as shown on the left.
4452
Processing Now. Please wait !
Once the adjustment has been completed, the Menu screen will appear. The offset value is input in Front offset that is included in the Set media type screen.
D-98
PT-R4300 SERVICE MANUAL
D.Operation panel 3-12-5.Centering Test screen 4451
Centering test
Front sensor offset
Allows you to perform the centering operation. OK Pressing the key after selecting the
Centering test Adjust Displacement sensor
Centering test
NVRAM backup
key brings up the plate type screen.
NVRAM restore
ESC
NEXT
OK
Press the OK key after selecting the plate type and the screen for execution confirmation appears.
1050
1
Plate 1
2
Plate 2
3
Plate 3
4
Plate 4
5
Plate 5
ESC
OK
NEXT
4451
OK
Pressing the OK key after setting the plate executes the centering operation.
Start OK ?
ESC
OK
CANCEL
The screen during the operation is as shown on the left.
4452
Processing Now. Please wait !
Once the operation has been completed, the screen shown on the left will appear and the op-
4050
Centering test
eration will be on standby. Waiting
ESC
Completes the centering operation and disESC
PT-R4300 SERVICE MANUAL
charges the plate.
D-99
D.Operation panel 3-12-6.Adjust Displacement Sensor screen 4451
Adjust displacement sensor
Front sensor offset Centering test Adjust Displacement sensor
Pressing the
NVRAM backup
Adjust displacement sensor
NVRAM restore
ESC
OK
It is used when adjusting the position to install the displacement sensor.
NEXT
4451
key after selecting the key plate type and the screen for OK
execution confirmation appears.
OK
Displays the screen for adjusting the position to
Start OK ?
ESC
OK
install the displacement sensor Secure the sensor to the position at the point that the buzzer sounds. • Allowable adjustment range when the black
CANCEL
tape for the displacement sensor is not affixed to the drum (s/n: up to 100): D7 ± 5 • Allowable adjustment range when the black tape for the displacement sensor is affixed to the drum. (s/n: 101 onward) A0 ± 5
The above-mentioned serial numbers (s/n) are s/ n of PT-R4000 (II). ESC
4050
Float sensor offset
Returns you to the upper layer Menu screen.
D4
ESC
D-100
PT-R4300 SERVICE MANUAL
D.Operation panel 3-12-7.NVRAM Backup screen NVRAM backup
4451
Front sensor offset Centering test Adjust Displacement sensor
Pressing the
NVRAM backup
NVRAM backup
NVRAM restore
ESC
Allows storing of the NVRAM data in the flash memory.
NEXT
OK
4451
key after selecting the key brings up the screen by which OK
you can store the NVRAM data in the flash memory.
OK Do you backup the data on NVRAM in Flash-Memory ?
Executes NVRAM data storing in the flash memory. • Always carry out this operation whenever you replace the RCP board.
ESC
OK
CANCEL
This enables you to restore the NVRAM data. • Before performing this operation, be sure to turn ON the DipSW bit 2 on the RCP board. Also be sure to return the setting to the original state after the operation has been completed. The screen during the operation is as shown on the left.
4452
Processing Now. Please wait !
PT-R4300 SERVICE MANUAL
D-101
D.Operation panel 3-12-8.NVRAM Data Restore screen NVRAM restore
4451
Front sensor offset Centering test Adjust Displacement sensor
Allows restoring of data from the flash memory to the NVRAM. Pressing the
NVRAM backup
NVRAM restore
NVRAM restore
key after selecting the key brings up the NVRAM data reOK
store screen. ESC
OK
NEXT
4451
OK Do you overwrite the deta on NVRAM with the data backup in Flash -Memory ?
ESC
Executes NVRAM data restoring to the NVRAM from the flash memory. • Always carry out this operation whenever you
OK
CANCEL
replace the RCP board. This enables you to restore the NVRAM data. • Before performing this operation, be sure to turn ON the DipSW bit 2 on the RCP board. Also be sure to return the setting to the original state after the operation has been completed. Once data restoring has been complated, the screen returns to the Menu screen.
D-102
PT-R4300 SERVICE MANUAL
D.Operation panel 3-12-9.Register Test screen 4452
Register test
Register test
Allows you to perform the centering and punching operations of the plate as well as to check the registration. Pressing the Register test
ESC
NEXT
OK
1050
1
Plate 1
2
Plate 2
3
Plate 3
4
Plate 4
5
Plate 5
ESC
key after selecting the
key brings up the plate type screen.
Place the plate that you wish to check the registration onto the insertion table. Press the OK key after selecting the plate type and the screen for execution confirmation appears.
OK
NEXT
4451
OK
Loads the plate and performs centering and punching operations.
Start OK ?
ESC
OK
OK
CANCEL
The screen during the operation is as shown on the left.
4452
Processing Now. Please wait !
PT-R4300 SERVICE MANUAL
Once the operation has been completed, the plate will be returned to the insertion table.
D-103
D.Operation panel 3-13.Special Action 2 screens 3052
Special action 2
Special action 2
Allows displaying of the maintenance jig command screens. Pressing the Special action 2
ESC
4460
OK
NEXT
Initialize
Performs step-by-step initialization. (Refer to D-105)
Mail test
Balancer test
Auto loader test
Tests the balancer operations.
Plate pad test OK
command screens.
Initialize
Balancer test
ESC
key after selecting the key brings up the maintenance jig OK
NEXT
(Refer to D-106)
Mail test NEXT
NEXT
Tests the mail function of the remote maintenance. (Refer to D-107) Auto loader test
Tests the auto loader operations. (Refer to D-108) Plate pad test
Tests the plate pad unit operations. (Refer to D-110) 4461
Paper pad test
Paper pad test
Tests the interleaf pad unit operations.
Multi auto loader test
(Refer to D-111)
Multi auto loader test ESC
D-104
OK
NEXT
Tests the multi auto loader operations. (Refer to D-112)
PT-R4300 SERVICE MANUAL
D.Operation panel 3-13-1.Machine Initialization screen 4460
Initialize
Initialize
Allows executing of step-by-step initialization. OK Pressing the key after selecting the
Balancer test Mail test
Initialize
Auto loader test
ization screen.
Plate pad test ESC
key brings up the machine initial-
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4461
Initialize
1:--2:Head, 3:2nd motor 4:Trans error check 5:Actuator 6:Main motor 7:Punch 8:Path up 9:Init. status
ESC
CLR
1
7
8
9
4
5
6
1
2
3
0
.
-
OK
1:--Not used. 2:Head Initializes the recording head. 3:2nd motor Initializes the sub shaft motor and returns it to the origin.
ENT
4:Trans error check Checks the transportation system errors. 5:Actuator Initializes the transportation system actuators. 6:Main motor Initializes the drum and then searches the balancers. 7:Punch Initializes the punch system. 8:Path up Raises the transportation section. 9:Init. status Initializes the data that controls the sequence. 4464
OK
Starts the selected initialization.
Start OK ?
ESC
OK
Once the initialization has been completed, the upper layer Menu screen will appear. CANCEL
PT-R4300 SERVICE MANUAL
D-105
D.Operation panel 3-13-2.Balancer Testing screen 4460
Balancer test
Initialize
Allows testing of the balancer operations. OK Pressing the key after selecting the
Balancer test Mail test
Balancer test
key brings up the screen by which you can test the balancer operations.
Auto loader test Plate pad test ESC
OK
ESC
NEXT
Returns you to the upper layer Menu screen. 4462
CLR Balancer test
1
7
8
9
4
5
6
1
2
3
Printing No. :
Note : No.0 is searching
0
ESC
OK
·
ENT
0
: Searches the balancers and displays their
positions. 1 to 15 : Moves the balancers to the appropriate positions depending on the plate size used in the specified printer setting. -1 to -15 : Displays the positions of balancers depending on the plate size used in the specified printer setting.
4464
OK
Starts Starts the selected initialization.
Start OK ?
ESC
D-106
OK
Once the initialization has been completed, the screen for balancer operations will appear. CANCEL
PT-R4300 SERVICE MANUAL
D.Operation panel 3-13-3.Mail Testing screen 4460
Mail test
Initialize
Allows testing of the mail function of the remote maintenance.
Balancer test Mail test
Pressing the
Auto loader test
Mail test
Plate pad test ESC
OK
NEXT
key after selecting the key brings up the mail testing OK
screen. ESC
Returns you to the upper layer Menu screen. 4469
CLR
Mail test 1 1-:Error 11-:Warning 21-:Request 31-:User Info 51-54:Relating light 55:Dummy communi.
ESC
7
8
9
4
5
6
1
2
3
0
.
OK
: Sends an error mail. : Sends a warning mail.
21 31
: Sends a work request mail. : Sends a user information mail.
51 to 54: Performs the pilot lamp test. 55 : Spare
ENT
4464
OK
Starts Starts the selected initialization.
Start OK ?
ESC
1 11
OK
Once the initialization has been completed, the mail testing screen will appear. CANCEL
PT-R4300 SERVICE MANUAL
D-107
D.Operation panel 3-13-4.Auto Loader Testing screen 4460
Auto loader test
Initialize
Allows testing of the auto loader operations. OK Pressing the key after selecting the
Balancer test Mail test
Auto loader test
key brings up the screen by which you can carry out various auto loader tests.
Auto loader test Plate pad test ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4463
1:Initialize 2:Disch. paper 3:Trans plate(1/2) 4:Cont. loader seq 5:Cont. all seq 6:Trans plate(2/2) 7:Cont. Multi seq
ESC
CLR
1
Auto loader test
OK
7
8
9
4
5
6
1
2
3
0
• ENT
1:Initialize Executes the initialization sequence. 2:Disch. paper Executes the interleaf discharge sequence. 3:Trans plate (1/2) Transports a plate to the AT section. 4:Cont. loader seq Executes the continuous operation of the SA-L by itself. (For individual unit adjustment) The system assumes that one sequence has been completed when the AT pass sensor turns OFF and then ON again. It then starts the next sequence. 5:Cont. all seq Sequentially executes SA-L (MA-L) operation, PT-R’s plate winding and discharge operations.
Before using this function in the MA-L, the desired cassette must be transported to the loader section beforehand using “11-13: Load cassette” of “Multi auto loader”. 6:Trans plate (2/2) Transports the plate at the AT section to the transportation table of the PT-R. 7:Cont. Multi seq
Please do not use this command since it is only used for debugging at the factory.
D-108
PT-R4300 SERVICE MANUAL
D.Operation panel 4464
OK
Starts Starts the selected initialization.
Start OK ?
ESC
OK
Once the initialization has been completed, the screen for balancer operations will appear. CANCEL
PT-R4300 SERVICE MANUAL
D-109
D.Operation panel 3-13-5.Plate Pad Unit Testing screen 4460
Plate pad test
Initialize
Allows testing of the plate pad unit operations. OK Pressing the key after selecting the
Balancer test Mail test
Plate pad test
key brings up the screen by which you can carry out various plate pad unit tests.
Auto loader test Plate pad test ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4466
1:Init, 3:Separation 2:Down until H1 on 4:Move to waiting pos 5/6:Vacume On/Off 7:Zone 1 8:Zone 2 9:Zone 3 10:Zone4 10:Close
ESC
CLR
1
Plate pad test
7
8
9
4
5
6
1
2
3
0
.
OK
ENT
1:Init Initializes the plate pad unit. 2:Down until H1 on Moves the plate pad unit until the pressure sensor shows the set value (H1). 3:Separation Executes the plate separation sequence. 4:Move to waiting pos Moves the plate pad unit to the position to which the interleaf pad is lowered. 5/6:Vacume On/Off Turns the vacuum pump ON or OFF. 7:Zone 1 Opens the Zone 1 valve of the plate pad. 8:Zone 2 Opens the Zone 2 valve of the plate pad. 9:Zone 3 Opens the Zone 3 valve of the plate pad. 10:Zone 4 Opens the Zone 4 valve of the plate pad. 11:Close Closes the plate pad valves.
4464
OK
Starts Starts the selected initialization.
Start OK ?
ESC
D-110
OK
Once the initialization has been completed, the plate pad unit testing screen will appear. CANCEL
PT-R4300 SERVICE MANUAL
D.Operation panel 3-13-6.Interleaf Pad Unit Testing screen 4461
Paper pad test
Paper pad test
Allows testing of the interleaf pad unit operations. OK Pressing the key after selecting the
Multi auto loader test
Paper pad test
key brings up the screen by which you can carry out various interleaf pad unit tests. ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4467
1:Init 3:Down metal 2:Judge 4:Suck paper 5:Up to nip 6/7:Vacume On/Off 8:Zone 1 9:Zone 2 10:Zone 3 11:Zone 4 12:Close
ESC
CLR
1
Paper pad test
7
8
9
4
5
6
1
2
3
0
.
OK
ENT
1:Init Initializes the interleaf pad unit. 2:Judge The paper pad is lowered to the paper/plate judgment position and stopped. 3:Down metal Moves the interleaf pad to the position where the metal sensor turns ON 4:Suk paper The paper suction is performed. 5:Up to nip Moves the interleaf pad to the interleaf rollers’ nipping position. 6/7:Vacume On/Off Turns the vacuum pump ON or OFF. 8:Zone 1 Opens the Zone 1 valve of the interleaf pad. 9:Zone 2 Opens the Zone 2 valve of the interleaf pad. 10:Zone 3 Opens the Zone 3 valve of the interleaf pad. 11:Zone 4 Opens the Zone 4 valve of the interleaf pad. 12:Close Closes the interleaf pad valves.
4464
OK
Starts Starts the selected initialization.
Start OK ?
Once the initialization has been completed, the interleaf pad unit testing screen will appear.
ESC
OK
CANCEL
PT-R4300 SERVICE MANUAL
D-111
D.Operation panel 3-13-7.Multi Auto Loader Testing screen 4461
Multi auto loader test
Paper pad test
Allows testing of the multi auto loader operations. OK Pressing the key after selecting the
Multi auto loader test
Multi auto loader test
key brings up the screen by which you can carry out various multi auto loader tests. ESC
OK
NEXT
ESC
Returns you to the upper layer Menu screen. 4468
CLR
Multi auto loader test 1 1:Initialize 2/3:Door Unlock/lock 4:Unload cassette 11-13:Load cassette 20-23:Lift position 5:C->Lift, 6:Lift->C
7
8
9
4
5
6
1
2
3
0 ESC
OK
1:Initialize Initializes the MA-L. 2/3:Door Unlock/lock Locks or unlocks the cassette door. 4:Unload cassette
•
Returns the cassette tray on the lift side to its original position.
ENT
11-13:Load cassette 11: Moves the 1st slot cassette tray to the lift side. 12: Moves the 2nd slot cassette tray to the lift side. 13: Moves the 3rd slot cassette tray to the lift side. The cassette tray stands by at the loading position height on the lift side. 20-23:Lift positioning 20: Moves the lift to the loading position height. 21: Moves the lift to the 1st slot cassette height. 22: Moves the lift to the 2nd slot cassette height. 23: Moves the lift to the 3rd slot cassette height. 5:C->Lift Moves the cassette tray from the cassette storing side to the lift side. 6:Lift->C Moves the cassette tray from the lift side to the
4464
cassette storing side.
Start OK ?
OK
Starts Starts the selected initialization. ESC
D-112
OK
CANCEL
Once the initialization has been completed, the multi auto loader testing screen will appear. PT-R4300 SERVICE MANUAL
E. Reference
E.Reference
PT-R4300(Ver1.00)Sequence
1.Sequence explanations (PT-R4300) 1-1.Initialization sequence
T h e p ro c e s sin g b e fo re in itia lizin g
S e rvo P a c k a la rm c h e c k in g
InitS eq1
T h e p ro c e s s in g o f p la te o n tra n s p a s s in itia liz in g
E rro r
It re s e ts S e rv o p a c k , if it o c c u r s o v e r lo a d a la rm
It re tu rn s to th e g e n e ra lly m o d e , if lo o p g a in o f s p e e d a n d in te g ra tio n c o n s ta n t a re a h ig h s p e e d tu rn m o d e .
T h e p ro c e s s in g o f a c u tu a te rs in itia liz in g
A fte r to m a k e in itia lizin g is o n c e e n d e d , it is n 't O ff a p o w e r s u p p ly ?
No
Yes
T h e p ro c e s s in g o f S V C in itia lizin g
S e rv o re s e t Yes
S e rvic e c a ll e rro r B o c c u rs No
It c h e c k s w h e th e r o r n o t p la te is le ft in th e e q u ip m e n t.
Ok
It c h e c k s lo a d a n d u n lo a d c o n d itio n w h ic h is m e m o riz e d in N v R a m
Is it in th e c la m p in g o n ly w ith le a d in g c la m p s ?
E q u a l to o r m o re th a n 5 d e v ia tio n c o u n te rs ? Yes
No
T h e s ta te a t w h ic h it re m o ve s ta il c la m p s b y d is c h a rg in g .
A d ju s tm e n t o f a u to m a tic a lly O ffs e t zero
No
D ru m : It d e c id e s o n th e p o s itio n o f S q u e e z e
Yes
InitS eq2
It d e c id e s o n th e ta rg e t p o s itio n o f s q u e e z e if n o t b e in g w ith in th e + -1 1 p u ls e a n d it re trie s 5 tim e s .
E rro r
E x1 1 b ,E x1 3 b E x1 6 7 ,E x1 6 e
E rro r
E x1 1 b ,E x1 3 b ,E x1 6 7 E x1 6 e ,E x1 7 5
E rro r
E x1 0 7 ,E x1 c 6 E x1 c 7
E rro r
E x1 1 b ,E x1 3 b E x1 6 6 ,E x1 6 d
E rro r
E x1 1 b ,E x1 3 b ,E x1 6 6 E x1 6 d ,E x1 7 4
Yes It lo w e rs s q u e e z e .
No
T h e s ta te a t w h ic h p la te is tra n s la te d fro m th e s u p p ly s id e b y th e w in d in g ?
Yes
InitS eq1
No
T h e s ta te a t w h ic h p la te is w ra p p e d a ro u n d d ru m a n d ta il c la m p s p u t o n drum .
It w a its 5 s e c o n d , a fte r it s e rv o O N .
InitS eq3 D ru m : It d e c id e s o n th e p o s itio n o f ta il c la m p s . Yes
No
InitS eq4
It d e c id e s o n th e ta rg e t p o s itio n o f ta il c la m p if n o t b e in g w ith in th e + -2 p u ls e a n d it re trie s 5 tim e s .
Yes E rro r
P ro c e s s in g o f p u n c h in g It c lo s e s s h u tte r No
InitS eq5 It lo w e rs t ra n s p a th
T o m a in p ro c e s s in g o f in itia liz in g
E x1 1 1
E rro r
E x1 0 4 ,E x1 c 2 ,E x1 c 3 E x1 c 4 ,E x1 c 5 ,E x1 c b
It re tu rn s p la te to th e d is c h a rg e s id e tra n s pass
End
PT-R4300 SERVICE MANUAL
E-1
E.Reference
PT-R4300(Ver1.00)Sequence
T he processin g o f actuaters initializing
InitSeq2
Do the tail clam ps m atch a Yes clam p arm ? No
It closes shutter C lamp bolts in the middle p o siti o n It raises clam p arm
It lo wers clam p arm
T o the d ru m lo ck p osition of th e clam p bo lt
It raises clam p arm
Erro r
Erro r
Erro r
Erro r
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
Erro r E x 1 0 6 ,E x 1 c6 ,E x 1 c7
Ex10a
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
It closes th leading clam p s
It returns the lock p in of drum
E x 1 0 e,E x 1 c 0 ,E x 1 c 1
Erro r
E x1 9b,E x19 c
Servo OFF
T he processing o f actuaters initializing
It raises niproller
It m em orizes th at plate is winded onto the drum in Nv Ram
End
Erro r
Ex101
End
InitSeq3
T he processing o f actuaters initializing
End
InitSeq4
E rro r r eco v e ry 4
End
InitSeq5
The punch m echanizm is initialized.
E rro r r eco v e ry 1
End
E-2
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4300(Ver1.00)Sequence
1-2.Main processing of initializing
Start Parallel processing
C hecking of supply door is open/close
Erro r
Interlock checking o f fra m e co v er
Erro r
T he reg istered p unch are Idled 5times.
Ex189
No
No
Yes End? E x 1 3 1 ,E x 1 3 2 ,E x 1 3 3 E x 1 3 4 ,E x 1 3 5 ,E x 1 3 6
Yes
B lower of drum resets af ter th a t O N
T he processing o f plate on trans p ass initializing
T h e 2 n d e rro r?
Ex14c
It returns the side align m ent m echan ism to th e sta rti n g p o in t .
Erro r
Erro r E x1 2d,E x13 f
B lower of drum is OFF End T he processing o f actuaters initializing
Erro r
B lower of drum is OFF After to m ak e initializing is once ended, it isn't Off a power supply?
Yes
No T he processing o f SVC Initializing
Servo reset
Servo ON , it waits 5seconds
It adjusts an offset autom atic zero if the deviatio n cou nter is equal to o r m ore th an 5.
Erro r
B lower of drum is OFF
Is plate wrapped on drum ?
Yes
Drum : It decides on tail clam p position(Nv R am m em orized) in th e p o siti o n
No
Do the tail clam ps m atch a clam p arm ?
B alancer search
Erro r Ex155
It d ecides o n the target positio n of tail clam p if n ot b ein g within the + -2pulse and it retries 5times.
Erro r
B lower of drum is OFF Servo OFF
It low ers tran s path E x 1 2 8 ,E x 1 5 1 ,E x 1 9 f E x 1 a0 ,E x 1 a1 ,E x 1 a2
T he B low er o peratio n checking
A
Erro r
Drum : It decides on leading clamp position in the p osition .
It d ecides o n the target positio n of leading clam p if not being within the +5pulse and it retries 5times.
It r etu r n s p l ate t o th e discharge side of trans pass
Sensor detected head is ON
It raises trans path
Servo OFF
Ex14f
Sensor detected head is OF F
Erro r
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
E x1 1b,E x13 b,E x 165 E x 1 6 c,E x 1 7 3
Erro r E x 1 7 c,E x 1 7 f
B lower of drum is OFF
Ex18c Drum vaccum pressure checking
Erro r
B lower of drum is OFF B lower of drum is Off
Is a pu nch o f o ptio n set t o O N ?
Yes
No P H 6 1 H /A ,P H 6 2 Sensor checking
Erro r
E x1 7b,E x17 d,E x 17e
Ex186 Sensor detected head is ON End It waits 1seco nd
A
PT-R4300 SERVICE MANUAL
E-3
E.Reference
PT-R4300(Ver1.00)Sequence
1-3.Processing of trans pass initializing Start
B o th P H 5 4 an d P H 7 0 detect plate? No
Yes
No
Is trans path at the high est positio n? Yes C lutch of supply side is OFF C lutch of discharge side is ON
T ran s m o to r: It tra n sf ers 66 0m m at speed o f 40 m m /s
Ex603
Is th ere plate o n sen sor of PH54 only? No
Yes
C lutch of supply side is OFF C lutch of discharge side is ON
T ran s m o to r: I t re tu rn plate u ntil P H5 4's O FF at 40 m m /s.
Erro r
T ran s m o to r is stop ped.
Ex145
Isn't there plate o n senso r of PH 59?
Yes
No E x 1 ce Ex14f
Is th ere plate o n sen sor of PH70 only?
Yes
Ex1b7
No Is th ere plate o n sen sor of PH59?
Yes
Ex14f
No Do sen sor o f PH 50 detect p la te?
Yes
No
Erro r It closes shu tter
It lo wers niproller.
End
Erro r
Ex102
Ex150 It op ens shu tter.
Erro r
Ex110
C lutch of supply side is ON C lutch of discharge side is OFF
T ran s m o t o r: It ret u rn s p la te until PH50's OFF at 50mm /s. B ut, it stops even if it doesn't OFF and it passes in the (194 .5/50 )sec.
It closes shutter.
Erro r
Ex111
Erro r It raises niproller
Ex150
T ran s m o to r: It tra n sf ers 31 .5m m at sp eed of 40 m m /s
Ex150
E-4
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4300(Ver1.00)Sequence
1-4.Processing of punch sequence Start
B
Yes
D o it d e te ct an in terlea f p a p e r?
Ex1c8 It lo w e rs n ip ro ller
Error
No It lo w ers tra n s p ath a t th e p u n ch p o sitio n .
Error
Sid e alig nm ent starting p oin t re tu rn
Error
*1
E x 1 0 4 ,E x 1 c 2 ,E x 1 c 3 E x 1 c 4 , E x 1 c 5 ,E x 1 c b
Ex102 D o e s it d ete ct a n in te rle af p a p e r?
It ra ises tra n s p ath
Yes
No
*1
E x 1 2 d ,E x 13 f It occurs an erro r w ithin the id ling of pu nch at p late b efo re .
Ex1c8
Yes
No
Idling o f pun ch
It d rive s th e se t p u n c h
Error
Error
*1 It ra ises tra n s p ath Error
It lo w e rs n ip ro ller
It ra ises tra n s p ath
E x 1 3 1 ,E x 1 3 2 ,E x 1 3 3 E x 1 3 4 ,E x 1 3 5 ,E x 1 3 6
E x 1 3 1 ,E x 1 3 2 ,E x 1 3 3 E x 1 3 4 ,E x 1 3 5 ,E x 1 3 6 P arallel p ro ce ssin g
C lu tch of su pply side is O N C lu tch of discharge side is O FF Ex102 Sid e alig nm ent starting p oin t re tu rn
Error
Error
It re tu rn b a ck p late to trans pass
Error
It o p e n s sh u tter Isn 't it p u n c h's O N a n d retryin g ? It ra ises tra n s p ath
*1
No
Error
Yes
It strik es a set p u n ch R e t ry
It ra is es n ip ro ller
E x 1 2 d ,E x 13 f
It clo se s sh u tte r.
Ex110 T ra n s m o to r: It tra n s p late u n til O N o f P H 62 se ns or a t 7 0 m m /s
It raise s n ip ro lle r.
T im e o u t Ex130 No
Is th e re p la te o n se n so r o f PH62?
Error It clo se s sh u tte r
Ex111
Yes
It raise s n ip ro ller an d it tran s p la te to se ns e ON of PH62.
Error
Is it p o ssib le to h a v e w ith draw n p late b y retrin g? Error It lo w e rs n ip ro ller
It ra is es n ip ro ller
Ex102
Error It o p e n s sh u tter
Ex1ca
No
D o e s it d ete ct a n in te rle af p a p e r?
Error
Yes
Yes
Ex110 No
E rro r r e c o v e ry 1
T ran s m o to r: if it's 0 .3 m m o f pla te th ick n e ss, it tran s b y in term issio n m al at 5 0 m m /s. If n o t it trans by continuo usly at 5 0 m m /s
Ex101
It ra ises tra n s p ath End
T ra n s m o to r : It re t u r n s p late u n til P H 5 0 's O F F a t 5 0 m m /s
T im e o u t It ra is es n ip ro ller No
It adju sts side alig nm ent ac co rd in g to th e p la te size.
Error
Is th e re p la te o n se n so r o f PH50? Ex1c8 Yes
It clo se s sh u tte r It waits 0.5 second .
Sid e alig nm ent m oto r: It m o v e 3 m m in re v e rs e at s pe ed of 5 m m /s
Error It trans plate to shu tter and it raises trans path at th e sa m e tim e .
Error
E x 1 0 1 ,E x 1 0 3 Ex111
T h e w a itn g tim e ac co rd in g to p late Ex12f Sid e alig nm ent m oto r: It m o v e 3 m m a t s p e e d o f 5 m m /s
Error
A fter 0 .5 se c, tran s m o to r is sto pped .
*1 Sid e alig nm ent starting p oin t re tu rn
It w aits 2s ec on d *1
E rro r r e c o v e ry 1 B
E x 1 2 d ,E x 1 5 6 ,E x 1 5 7 E x 1 5 8 ,E x 1 c 9
PT-R4300 SERVICE MANUAL
E-5
E.Reference
PT-R4300(Ver1.00)Sequence
1-5.Processing of winding sequence Start C P arallel p ro ce ssin g
D o e s it d e tec t a lea f p a p er?
It lo w ers tra n s p ath .
Error
Error
Ex1c8
It closes lead ing clam p s
Error
T ra n s m o t o r : s to p It o p en lea d in g c lam p s
T ra n s m o t o r : s to p C lutch of supply sid e is O ff.
E x 1 0 4 ,E x 1 c 2 ,E x 1 c 3 E x 1 c 4 , E x 1 c 5 ,E x 1 c b
E rro r r e c o v e ry 1 D rum : It decides o n the leadin g clam p p osition
Error S erv o O N W hen the SV C status do esn't R eady, it adju sts and it retries an au to m atic o ffset ze ro if n ev e r retry in g
It retu rn s th e b oth side dru m lo cking pin .
D rum : It decides o n the po sition of squeeze
E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
Error
No
It de cid e s o n th e target squeeze p o sitio n if n ot b ein g w ithin+ -11p ulse an d it retrie s
E x 1 1 b ,E x 13 b ,E x 1 6 5 Ex16c,Ex173
Error
E rro r r e c o v e ry 2 L ead ing edg e detection se nso r O N
Yes
E x 1 1 b ,E x 13 b ,E x 1 6 7 Ex16e,Ex175
Ex1c8
No
It low ers sq ueeze roller. No
Error
L ead ing edg e detection se nso r O F F
E x1b0
B low er of d rum is O N
It puts out the d rum lock ing p in
It lo wers squeeze roller to a ha lf
Error
Ex810
Yes
A re th ere ta il clam p s in th e cla m p arm ?
E x 1 9 b ,E x 19 c
No
It decid es on target leadin g clam p in the p o sitio n if n ot b ein g w ithin + -3and it retries.
D o e s it d ete ct a n in terlea f p a p e r?
Error
P arallel p ro ce ssin g
It adjusts an o ffset au to m atic zero if th e deviation coun ter is equal to o r m o re th a n 5 .
Is th ere p late in th e su p p ly side?
Yes
Ex10e,Ex1c0 Ex1c1
It raises squeeze roller
Error
E x 1 9 9 ,E x 1 9 a
E rro r r e c o v e ry 2
E x 1 0 7 ,E x 1 c 6 ,E x 1 c 7
Servo O FF P arallel p ro ce ssin g It op e n s lea d in g c lam p s
It lo w e rs n ipro ller
Error
Error
E x 1 0 f ,E x 1 c 0 Ex1c1
D isp lac em e n t se n so r checkin g.
Error
It d e cid es o n th e p os itio n o f ta il clam p o f d ru m .
M id dle po sition o f clam p bo lt
Error
Error
R ec ov e ry o f th e siz e e rr o r
It m a ke s a c lam p b o lt a dru m unlo cking position .
E x 1 1 2 ,E x 1 1 5 ,E x 1 1 b E x 1 3 b ,E x 1 6 6 ,E x 1 6 d
E rro r r e c o v e ry 4
C lutch of su pply side is O N C lutch of discharge sid e is O FF
Error
Error
Ex102 E x 1 1 b ,E x 1 1 c ,E x 1 2 7 E x 1 3 b ,E x 1 5 d
It o p e ns sh u tter
T he leading edg e p o sitio n c h ec k ing
E rro r r e c o v e ry 4
E x 1 b 9 ,E x 1 3 9
Ex110 Ex10a
T ra n s m o t o r: It tra n s p l a te (1 30 + A )m m a t sp ee d 1 0 5 m m /s. A is the revision v alue w hich is p ec u lia r to th e m a ch in e.
It ra ise s n ipro ller
T h e v ac cu m p ressu re ch e ck in g
Error
E rro r r e c o v e ry 4
Error
E rro r r e c o v e ry 1 Ex186
T ran s m o to r : d riv in g o f sp eed 5 0m m /s Ex101 D o e s it d ete ct a n in terlea f p a p e r?
It d etec ted a n in te rle af p a p e r?
Yes
Yes No E rro r r e c o v e ry 4
No T ra n s m o to r : s to p It w aits 2secon ds
Ex1c8 E rro r r e c o v e ry 1
C
It de cid e s o n th e targ et tail cla m p p o sitio n if n ot b ein g w ithin +-3 pulse and it retrie s
Ex1c8
D
E-6
Error
E rro r r e c o v e ry 4
E x 1 1 b ,E x 13 b ,E x 1 6 6 E x 1 6 d ,E x 1 7 4
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4300(Ver1.00)Sequence
D
It lo wers clam p arm
Erro r
It m akes a clam p bolt a drum unlocking position. It closes shutter It raises a clam p arm in th e middle position.
E rro r r eco v e ry 4
E x 1 0 6 ,E x 1 c6 ,E x 1 c7 It m ak es a clam p b olt the po sition of th e drum locking.
Erro r
It m akes a clam p bolt a drum unlocking position.
It raises a clam p arm in th e middle position.
E rro r r eco v e ry 4
Ex10a It m ak es a clam p b olt the po sition of th e drum locking.
It m akes a clam p bolt a drum unlocking position.
Erro r
M o re th an retry tw o tim es?
No
Yes It m akes a clam p bolt a drum unlocking position.
It raises a clam p arm in th e middle position.
E rro r r eco v e ry 4
Ex1b2 It m em orizes th e d ru m present p ositio n as th e po sition w hich tail clam ps were p ut on.
It raises clam p arm
Erro r
Is tail clam ps locked up the drum?
Erro r
T he blow er o peratio n checking
Erro r
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
Ex11d
Ex18c
End
PT-R4300 SERVICE MANUAL
E-7
E.Reference
PT-R4300(Ver1.00)Sequence
1-6.Discharge Sequence
E
Start
Parallel op eration
T ran s m o to r: It re tu rn plate at th e speed o f 125m m/s. Erro r
It low ers tran s path
It returns drum locking pin
Erro r
E x 1 0 4 ,E x 1 c 2 ,E x 1 c 3 E x 1 c4 ,E x 1 c5 ,E x 1 cb C lutch of the discharge side is OFF.
E x1 9b,E x19 c Parallel op eration
Drum : It decides on the po sition of tail clam p
It d ecides o n the target tail clam p po sition if not b ein g within +-2pulse and it retries
Do in g PH5 4 and PH 59 sensor Plate deing?
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 6 ,E x 1 6 d
If it becom es the po sition of 1 50m m to a leading clam p position, it is begun to raise a squeeze roller
Erro r
Drum : It decides on the po sition of lead in g clam p
T ran s m o to r : sto p Erro r
E x1 1b,E x13 b,Ex 16 6 E x 1 6 d ,E x 1 7 4 E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
Yes
No
It raises trans path
It d ecides o n the target leading clam p po sition if not b ein g within + -3 and it retries until 5tim es.
Erro r
T ran s m o to r : sto p Ex143
Is there tail clam p in th e clam p arm .
Yes
E x1 1b,E x13 b,Ex 16 5 E x 1 6 c,E x 1 7 3
Ex1b1
No It m ak es a clam p bolt the po sition of th e drum locking.
It puts out the drum locking pin. Erro r
Erro r
E x 1 9 9 ,E x 1 9 a
Ex10a T ran s m o to r : sto p
It lo wers clam p arm
It m ak es a clam p bolt the po sition of th e drum unlocking.
Erro r
It raises clam p arm
C lutch of the supply side Off. C lutch of the discharge side is ON
E x 1 0 6 ,E x 1 c 6 ,E x 1 c 7
Servo OFF
Erro r Is it senso r of P H54 O FF? It m akes a clam p bo lt po sition of th e drum locking.
Yes
Ex11f
No
It o pens lead in g clam p s
Erro r
E x 1 0 f,E x 1 c 0 ,E x 1 c1
It raises clam p arm Drum blower OFF
Ex109
T ran s m o to r: It re tu rn s un til P H54 O FFs at th e speed of 160m m/s.
Erro r
C lutch of the supply side is OFF C lutch of the discharge side is OFF
It raises a clamp arm in the m idd le po sition .
T ran s m o to r : sto p
Erro r
Ex11f Yes It lo wers clam p arm
Is it senso r of P H59 O FF? No
It m ak es a clam p bolt the po sition of th e drum locking.
Is there p late to wind con tinu ously?
E x 1 ce Yes
No It raises clam p arm It closes leading clam ps
Erro r
E x 1 0 e,E x 1 c0 ,E x 1 c1
E x 1 0 8 ,E x 1 c 6 ,E x 1 c 7 It retu rn s d ru m lo cking pin Is there tail clam p in th e clam p arm ?
Erro r
Erro r
E x1 9b,E x19 c
Ex11d
End E
E-8
PT-R4300 SERVICE MANUAL
E.Reference
E rro r rec o v ery 1
It r etu r n s p l ate t o th e side of supply plate.
PT-R4300(Ver1.00)Sequence
E rro r rec o v ery 3
Erro r B lower of drum is OFF
It retried?
No It op ens shu tter
Erro r
Ex110
Yes
It closes shu tter
It closes shu tter
Drum : It decides on the position of squeeze
E x 1 0 2 ,E x 1 1 0 ,E x 1 4 6
It d ecides o n the target squeeze po sition if not b eing within +-11 and it retries.
Erro r
Ex111
It raises clam p arm
Erro r
Erro r
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 7 ,E x 1 6 e
E x1 1b,E x13 b,E x 167 E x 1 6 e,E x 1 7 5
E x 1 0 5 ,E x 1 c 6 ,E x 1 c 7
T ran s m o to r : st o p
E rro r rec o v ery 2 It raises niproller
Erro r
It raises trans path C lutch on the supply side is OF F
End
Ex101
It closes leading clam ps
Erro r
E rro r R e co v e ry 4
It raises trans path Do sen sor of PH5 4 d etect p la te? E x 1 0 e,E x 1 c0 ,E x 1 c1
It raises trans path
Erro r
E x 1 0 3 ,E x 1 c 2 ,E x 1 c 3 E x 1 c4 ,E x 1 c5 ,E x 1 cb
Yes
Ex142
No
It low ers tran s path
Erro r
E x 1 0 4 ,E x 1 c 2 ,E x 1 c 3 E x 1 c4 ,E x 1 c5 ,E x 1 cb
B lower of drum is OFF End
T ran s m o to r : st o p E rro r rec o v ery 2
It discharg es plate to the discharge side of pass. B lower of drum is OFF
End Do in g PH5 0 senso r, plate being?
Yes
Drum : It decides on the position of leading clamp.
Erro r
It d ecides o n the target leading clam p po sition if not b eing within +-3 and it retries.
It returns drum locking pin
Erro r
Ex000
E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
E x1 1b,E x13 b,E x 165 E x 1 6 c,E x 1 7 3
R ecov ery o f size error
Do sen sor of PH5 0 d etect p la te?
Yes
No
Erro r
Erro r Drum : It decides on the tail clam p po sition with Y size of 650 m m in the p ositio n. B ut it stops drum forcing wh en plate p asses PH 50 senso r.
E x1 9b,E x19 c
E x 1 1 5 ,E x 1 1 b ,E x 1 1 c E x 1 2 7 ,E x 1 3 b
Servo OFF
It o pens lead in g clam p s
B lower of drum is OFF
Erro r
E x 1 0 f,E x 1 c 0 ,E x 1 c 1
E rro r rec o v ery 1
End
Drum : It decides on the tail clam p po sition with the Ysize which calculated fro m th e p o siti o n o f P H 5 0 senso r OF F in the positio n.
Erro r
E x1 1b,E x11 c E x 1 2 7 ,E x 1 3 b
It closes shu tter
E rro r rec o v ery 4
End
PT-R4300 SERVICE MANUAL
E-9
E.Reference
PT-R4300(Ver1.00)Sequence
1-7.Drum high speed rotating sequence The acceleration
Deceleration
Erro r T he all kind checking (* 1)
E x 1 4 c,E x 1 4 e,E x 1 5 f E x 1 6 1 ,E x 1 6 2 ,E x 1 6 4 Ex18c
T u rn S to p co m m an d
It w aits for the sp eed agreement signal and the speed Zero signal to ON. T he tim e out is 15 seco nds.
Drum h ig h speed rotation error latch signal clear.
Erro r
Erro r Vaccum pressure checking
Ex186
Erro r
E x 1 4 c,E x 1 4 e,E x 1 5 f E x 1 6 1 ,E x 1 6 2 ,E x 1 6 4 Ex18c
Yes
E x 1 5 f,E x 1 6 4 ,E x 1 8 8 E x 1 a3 ,E x 1 a4
T he all kind checking (* 1) It waits 1seco nd
Loose plate checking is enable Vaccum pressure checking is enable
B it2,5 of address 05h are ON No
It sets sp eed loop gain and In t eg ra tio n c o n stan t to high speed rotational m ode
It w aits for the sp eed agreement signal and the speed Zero signal to ON. T he tim e out is 15 seco nds.
Start com mand of drum high sp eed ro tatio n
T he b alancer po sito n checking
Erro r
It clears drum high speed rotation erro r latch sig nal Ex15b L oo se plate latch signal ch eck E r r o r Loose plate latch signal disable
Ex15e
Erro r It waits 2seconds T he vaccum pressure decline latch signal checking Vaccum pressure checking disable
*2
Erro r T he all kind checking (* 1)
*3
T h e E rr o r o f st o p p ed tim eou t
Erro r Ex188
Erro r Ex183
Yes B it4 of address fc00h is ON
Ex180 It clears SVC mode, a distance, a speed register
No Yes Speed OK?
It m ak es speed loo p gain, In t eg ra tio n c o n stan t to generally m od e.
No It waits until it reaches specification speed.
Erro r End *2
Erro r T he all kind checking (* 1)
*3
Yes B it4 of address fc00h is ON
Ex181
No
It waits 0.5 second until the turn is stable.
Erro r
*2
Erro r T he all kind checking (* 1)
*3
Yes B it4 of address fc00h is ON
Ex180
*1 Serv o sto p (L S 58-1,-2, S W 58 ) C ov er interlock (LS 57 -1,-2 ,-3) A ctu a ter (P H 2 0 ,P H 1 1 -2 A ,P H 1 1 -2 H ,P H 3 0 ,P H 3 0 H ) Drum blower (INVAL M )
*2
*3
Drum sto p
Drum sto p
E x 1 5 e,E x 1 8 4 ,E x 1 8 5 E x 1 8 8 ,E x 1 a 3 ,E x 1 a 4
E x 1 4 c ,E x 1 4 e ,E x 1 5 f E x 1 6 1 ,E x 1 6 2 ,E x 1 6 4 Ex18c
No B it2 of address fc00h is OF F
Yes Ex181
No End
E-10
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4300(Ver1.00)Sequence
1-8.Auto Balance Sequence
B alancer m ov em en t processing
Start
It calcu lates the po sition of balancer fro m plate size and thickness.
Yes T h e m o v em en t d ista n ce o f balancer w hich m o ves to the 1st is within 3pulse? No
It fixes th e order and the po sition wh ich m oves balancers (Home side)
T h e m o v em en t d ista n ce o f balancer w hich m o ves to the 1st is within 3pulse?
Erro r
E x1 1b,E x13 b,E x 168 E x 1 6 f,E x 1 7 6
Erro r
W h en bum p in g b y the balancer m o vem ent, it m o v es o n e to t h e te m p o r ary p o sit io n .
Detection o f balan cer
E x 1 2 0 ,E x 1 9 d
B alancer search Erro r It puts out balancer pin
Yes B alancer m ov em en t processing (H om e Side)
Erro r
E x 1 9 9 ,E x 1 9 a
E x1 20 an d less than retry two tim es? Erro r It m oves 1 st balan cer
No
E x 1 1 b ,E x 1 3 b E x 1 6 9 ,E x 1 7 0
Servo OFF Erro r It returns balancer pins.
E x1 9b,E x19 c
Erro r Detection o f balan cer
It fixes th e order and the po sition wh ich m oves balancers (Away side)
It renews the present drum Po sition as the positio n of balancer.
W h en bum p in g b y the balancer m o vem ent, it m o v es o n e to t h e te m p o r ary p o sit io n .
B alancer search Yes
B alancer m ov em en t processing (Away side)
E x 1 2 1 ,E x 1 9 e
Erro r
Ex19d and less than two times. No
Servo OFF
Yes T h e m o v em en t d ista n ce o f balanser which m oves to the 2nd is within 3pulse? No It d oes the 1 processing
End
End
PT-R4300 SERVICE MANUAL
E-11
PT-R4000II (Ver4.0X)Sequence
E.Reference
2.Sequence explanations (PT-R4000II) 2-1.Initialization sequence
The processing before initializing
Servo Pack alarm checking
InitSeq1
T he processing o f plate on tran s p ass initializing
Erro r
It resets Servo p ack , if it occur sover load alarm
It re tu rn s to th e generally mode, if loop g ain of speed and integration con stant are a hig hspeed turn m ode.
T he processing o f acutuaters initializing
After to m ak e initializing is once ended, it isn't Off a power supply?
No
Yes T he processing o f SVC initializing
Servo reset Yes
Service call error B occurs No
It checks wh eth er or no t plate is left in the equ ipm en t.
Ok
It checks load and unload condition which is m em orized in Nv R am
Is it in the clam ping o nly with leading clamps?
E qu al to or m o re th an 5 dev iatio n co unters? Yes
No
T he state at w hich it removes tail clam ps by discharging.
Ad ju stm en t of autom atically Offset zero
No
Drum : It decides on the position of Squeeze
Yes
InitSeq2
It d ecides o n the target positio n of squeeze if not being within the +-11pulse and it retries 5times.
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 7 ,E x 1 6 e
Erro r
E x1 1b,E x13 b,E x 167 E x 1 6 e,E x 1 7 5
Erro r
E x 1 0 7 ,E x 1 c 6 E x 1 c7
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 6 ,E x 1 6 d
Erro r
E x1 1b,E x13 b,E x 166 E x 1 6 d ,E x 1 7 4
Yes It lowers squeeze.
No
InitSeq3 Drum : It decides on the po sition of tail clam p s.
T he state at wh ich p late is translated from th e sup ply side by the winding?
Yes
InitSeq1
No
T he state at wh ich p late is wrapped around drum and tail clam ps put on drum.
It waits 5second, after it servo ON .
Yes
No
InitSeq4
It d ecides o n the target positio n of tail clam p if n ot b ein g within the + -2pulse and it retries 5times.
Yes Erro r
Processing o f p un ch in g It closes shu tter No
InitSeq5 It low ers tran s path
T o m ain p ro cessing o f initializing
Ex111
Erro r
E x 1 0 4 ,E x 1 c 2 ,E x 1 c 3 E x 1 c4 ,E x 1 c5 ,E x 1 cb
It r etu r n s p l ate to th e discharge side trans pass
End
E-12
PT-R4300 SERVICE MANUAL
E.Reference
T he processin g o f actuaters initializing
InitSeq2
Do the tail clam ps m atch a Yes clam p arm ? No
PT-R4000II (Ver4.0X)Sequence
It closes shutter C lamp bolts in the middle p o siti o n It raises clam p arm
It lo wers clam p arm
T o the d ru m lo ck p osition of th e clam p bo lt
It raises clam p arm
Erro r
Erro r
Erro r
Erro r
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
Erro r E x 1 0 6 ,E x 1 c6 ,E x 1 c7
Ex10a
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
It closes th leading clam p s
It returns the lock p in of drum
E x 1 0 e,E x 1 c 0 ,E x 1 c 1
Erro r
E x1 9b,E x19 c
Servo OFF
T he processing o f actuaters initializing
It raises niproller
It m em orizes th at plate is winded onto the drum in Nv Ram
End
Erro r
Ex101
End
InitSeq3
T he processing o f actuaters initializing
End
InitSeq4
E rro r r eco v e ry 4
End
InitSeq5
The punch m echanizm is initialized.
E rro r r eco v e ry 1
End
PT-R4300 SERVICE MANUAL
E-13
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-2.Main processing of initializing Start Parallel processing
C hecking of supply door is open/close
Erro r
Interlock checking o f fra m e co v er
Erro r
T he reg istered p unch are Idled 5times.
Ex189
No
No
Yes End? E x 1 3 1 ,E x 1 3 2 ,E x 1 3 3 E x 1 3 4 ,E x 1 3 5 ,E x 1 3 6
Yes
B lower of drum resets af ter th a t O N
T he processing o f plate on trans p ass initializing
T h e 2 n d e rro r?
Ex14c
It returns the side align m ent m echan ism to th e sta rti n g p o in t .
Erro r
Erro r E x1 2d,E x13 f
B lower of drum is OFF End T he processing o f actuaters initializing
Erro r
B lower of drum is OFF After to m ak e initializing is once ended, it isn't Off a power supply?
Yes
No T he processing o f SVC Initializing
Servo reset
Servo ON , it waits 5seconds
It adjusts an offset autom atic zero if the deviatio n cou nter is equal to o r m ore th an 5.
Erro r
B lower of drum is OFF
Is plate wrapped on drum ?
Yes
Drum : It decides on tail clam p position(Nv R am m em orized) in th e p o siti o n
No
Do the tail clam ps m atch a clam p arm ?
B alancer search
Erro r Ex155
It d ecides o n the target positio n of tail clam p if n ot b ein g within the + -2pulse and it retries 5times.
Erro r
B lower of drum is OFF Servo OFF
It low ers tran s path E x 1 2 8 ,E x 1 5 1 ,E x 1 9 f E x 1 a0 ,E x 1 a1 ,E x 1 a2
T he B low er o peratio n checking
A
Erro r
Drum : It decides on leading clamp position in the p osition .
It d ecides o n the target positio n of leading clam p if not being within the +5pulse and it retries 5times.
It r etu r n s p l ate t o th e discharge side of trans pass
Sensor detected head is ON
It raises trans path
Servo OFF
Ex14f
Sensor detected head is OF F
Erro r
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
E x1 1b,E x13 b,E x 165 E x 1 6 c,E x 1 7 3
Erro r E x 1 7 c,E x 1 7 f
B lower of drum is OFF
Ex18c Drum vaccum pressure checking
Erro r
B lower of drum is OFF B lower of drum is Off
Is a pu nch o f o ptio n set t o O N ?
Yes
No P H 6 1 H /A ,P H 6 2 Sensor checking
Erro r
E x1 7b,E x17 d,E x 17e
Ex186 Sensor detected head is ON End It waits 1seco nd
A
E-14
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-3.Processing of trans pass initializing Start
B o t h P H 5 4 an d P H 7 0 d etect p late? No
Yes
No
Is trans p ath at the h ig hest p ositi on ? Yes C lutch of supply side is O FF C lutch of discharge side is O N
T ra n s m o to r: It tran sfers 6 45 m m a t sp eed o f 4 0m m /s
Ex603
Is th ere p late o n sen so r of PH 5 4 o nly? No
Yes
C lutch of supply side is O FF C lutch of discharge side is O N
T ra n s m o to r: It re tu rn p late u nti l P H 5 4's O FF at 4 0 m m /s.
E r ro r
T ran s m o to r i s sto pp ed .
Ex145 T ra n s m o t o r : It t ra n s p late 1 0m m at 4 0m m / s
E r ro r
T ran s m o to r i s sto pp ed .
Ex14f Isn't the re p late on senso r of PH54?
Yes
No It retries at o n ce Ex14f Ex124 Is th ere p late o n sen so r of PH 7 0 o nly?
Yes
Ex1b 7
No D o sen so r o f PH 5 0 d etect plate?
Yes
No
E r ro r It closes sh utter
It lo w e rs n ip rol ler.
End
E r ro r
Ex102
Ex150 It op en s sh ut ter.
E r ro r
Ex110
C lutch of supply side is O N C lutch of discharge side is O FF
T ra n s m o to r: It re tu rn s p l a t e until PH 50's O FF at 50m m /s. B ut, it stops even if it doesn't O FF and it passes in the (1 94 .5 /5 0)sec.
It closes shu tte r.
E r ro r
Ex111
E r ro r It raises n iproll er
Ex150
T ra n s m o to r: It tran sfers 3 1.5 m m at sp eed o f 4 0m m /s
Ex150
PT-R4300 SERVICE MANUAL
E-15
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-4.Processing of punch sequence S tart
B
Y es
D o it d etect an in te rleaf p a p e r?
E x 1 c8 E r ro r
It lo w ers n ip ro ller No It lo w ers tran s p ath at th e p u n ch p o sitio n .
E r ro r
S id e alig n m en t sta rtin g p o in t retu rn
E r ro r
*1
E x 1 0 4 ,E x 1 c2 ,E x 1 c 3 E x 1 c4 ,E x 1 c 5 ,E x 1 c b
Ex102 D o es it de tect an in terle af p a p e r?
It raises tran s pa th
Y es
No
*1
E x 1 2 d ,E x 1 3 f It o ccu rs an erro r w ith in th e id ling of punch at p late b efo re.
E x 1 c8
Y es
No
Id lin g o f p u n ch
E r ro r
It driv es th e set pu nch
E r ro r
*1 It raises tran s pa th E r ro r
It lo w ers n ip ro ller
It raises tran s pa th
E x 1 3 1 ,E x 1 3 2 ,E x 1 3 3 E x 1 3 4 ,E x 1 3 5 ,E x 1 3 6
E x 1 3 1 ,E x 1 3 2 ,E x 1 3 3 E x 1 3 4 ,E x 1 3 5 ,E x 1 3 6 S id e alig n m ent sta rtin g p oint return
E r ro r
*1 Ex102 E r ro r It op ens shu tter
E x1 2d ,E x 13 f
It raises tran s pa th E r ro r
It retu rn back plate to trans pass
C lutch of supply side is O N C lutch of discharg e side is O F F It raises n ip ro ller
Isn 't it p u n ch 's O N an d re trying ? No
It w aits 0 .5 seco n d
E r ro r
Y es
It strik es a set pu nch
Ex110 R e try T ra n s m o to r: It tra n s p late u n til O N o f P H 6 2 sen so r a t 4 0 m m /s
It closes shu tter.
T im e o ut
No
Is there p late on sen so r o f PH62?
It raise s n ip ro ller.
Y es
It raise s n ip ro ller an d it trans p late to sen se ON of PH62.
Ex130 E r ro r E r ro r E r ro r
It closes sh utte r
It lo w ers n ip ro ller
It raises n ip ro ller
E r ro r It op ens shu tter
E r ro r
Ex110
E rro r rec o v e ry 1
T ran s m o to r: if it's 0 .3 m m o f p late th ic k n ess, it tran s b y in term issio n m a l at 5 0 m m /s. If n o t it tran s by continuously at 5 0 m m /s
Ex101
Y es
Is it po ssible to hav e w ithdraw n plate by retring?
E x 1 ca
No T ra n s m o to r : It re tu rn s p late u n til P H 5 0 's O F F at 5 0m m /s
T im e o u t
Y es
Is it set punch's O N ? No No
It ad ju sts sid e align m en t acc ord ing to th e plate size.
Ex111
Ex102
E r ro r
It idles the se t p un ch .
Is there p late on sen so r o f PH50? Y es
It closes sh utte r
D o es it de tect an in terle af p a p e r?
Y es
It w aits 1 seco n d . No It raises tran s pa th S id e alig n m en t m o to r: It m o v e 3 m m in re v e rse at speed o f 5m m /s
End E r ro r It tran s p late to sh u tter an d it raises tran s p ath at th e sam e tim e.
E r ro r
It raises n ip ro ller
E x 1 0 1 ,E x 1 0 3 Ex111
T h e w aitn g tim e acc ord ing to p late
E x 1 c8 Ex12f
S id e alig n m en t m o to r: It m o v e 3 m m a t sp ee d o f 5 m m /s
E r ro r
A fter 0 .5 sec , tran s m o to r is stopped.
*1 S id e alig n m ent sta rtin g p oint return
It w a its 5 seco n d *1
E rro r rec o v e ry 1 B
E-16
E x 1 2 d ,E x 1 5 6 ,E x 1 5 7 E x 1 5 8 ,E x 1 c9
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-5.Processing of winding sequence S tart C Pa rallel p ro cessin g
D o es it d etect a leaf p ap er?
It lo w ers tran s path .
E r ro r
E r ro r
E x 1 c8
E x 1 0 4 ,E x 1 c2 ,E x 1 c 3 E x 1 c4 ,E x 1 c 5 ,E x 1 c b
It closes leading clam ps
E r ro r
T ra n s m o to r : st o p It op en lead in g clam p s
T ra n s m o to r : st o p C lutch of supply side is O ff.
E rro r rec o v ery 1 D rum : It decides on th e lead in g clam p p o sitio n
E r ro r S e rv o O N W h en th e SV C status doesn 't R eady, it ad justs an d it retries an au to m atic offset zero if ne ver retrying
It ad ju sts an o ffset au to m atic zero if th e deviation counter is equal to o r m o re th an 5 .
No
E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
It decides on targ et lead in g clam p in th e p o sitio n if n o t b ein g w ith in +-3 an d it retries.
E r ro r
E x1 1b ,E x 13 b,E x1 65 E x 1 6 c ,E x 1 7 3
Y es
E x 1 0 e ,E x 1 c 0 E x 1 c1
It retu rn s the bo th side drum locking pin.
D rum : It decides on the position of squeeze
It d ecid es o n th e targ et squeeze p o sitio n if n o t b ein g w ith in + -11pulse and it re tries
E r ro r
E x1 9b ,E x 19 c
E r ro r
E r ro r
E rro r rec o v ery 2 Is th ere p late in th e sup p ly side?
No
Ex810
L e adin g ed g e d etection sen so r O N E x 1 1 b ,E x 1 3 b ,E x 1 6 7 E x 1 6 e ,E x 1 7 5
Y es
D o es it de tect an in terle af p a p e r?
Y es
It lo w ers sq ueeze ro ller.
E r ro r
E x 1 c8 L e adin g ed g e d etection sen so r O F F
No
A re th ere tail cla m p s in th e clam p arm ?
No
Ex1b0 It raises squeeze roller
B lo w er o f d ru m is O N E rro r rec o v ery 2 It p u ts o u t th e d ru m lo cking pin
E r ro r
E x 1 9 9 ,E x 1 9 a E x 1 0 7 ,E x 1 c6 ,E x 1 c 7 Pa rallel p ro cessin g
S erv o O F F
It o p en s lea d in g clam p s
It lo w ers n ip ro ller
E r ro r
E r ro r
E x 1 0 f,E x 1 c0 E x 1 c1
It d ecid es o n th e p o sitio n o f tail cla m p o f drum .
M iddle position of clam p bolt
E r ro r
E r ro r
R ec ov ery of th e size e rro r
It m ak es a c lam p b olt a drum unlocking position.
E x 1 1 2 ,E x 1 1 5 ,E x 1 1 b E x 1 3 b ,E x 1 6 6 ,E x 1 6 d
E rro r rec o v ery 4
The leading edge p o sitio n ch eck in g
E r ro r
E rro r rec o v ery 4
Ex102
C lutch of supply side is O N C lutch of discharg e side is O F F
E x 1 b 9 ,E x 1 3 9
Ex10a It op ens shu tter
E r ro r
Ex110
T he v acc um p re ssu re ch eck in g
It w aits 5seconds
E r ro r
E rro r rec o v ery 4 T ra n s m o to r: It tra n s p la te (1 3 0 + A )m m at sp eed 70 m m /s. A is th e revisio n v alu e w h ich is p eculiar to th e m achin e.
It raises n ip ro ller
Ex186
E r ro r
It d ete cte d an in terleaf p a p e r?
Y es
No E rro r rec o v ery 1
E rro r rec o v ery 4
T ran s m o to r : d riv in g o f sp eed 50m m /s Ex101 D o es it de tect an in terle af p a p e r?
Y es
No T ra n s m o t o r : sto p
E x 1 c8 It d ecid es o n th e targ et tail clam p p o sitio n if n o t b ein g w ithin +-3pulse and it re tries
E r ro r
E rro r rec o v ery 4
It w aits 3seconds E rro r rec o v ery 1 D
E x 1 1 b ,E x 1 3 b ,E x 1 6 6 E x 1 6 d ,E x 1 7 4
C E x 1 c8
PT-R4300 SERVICE MANUAL
E-17
E.Reference
PT-R4000II (Ver4.0X)Sequence
D
It lo wers clam p arm
Erro r
It m akes a clam p bolt a drum unlocking position. It closes shutter It raises a clam p arm in th e middle position.
E rro r r eco v e ry 4
E x 1 0 6 ,E x 1 c6 ,E x 1 c7 It m ak es a clam p b olt the po sition of th e drum locking.
Erro r
It m akes a clam p bolt a drum unlocking position.
It raises a clam p arm in th e middle position.
E rro r r eco v e ry 4
Ex10a It m ak es a clam p b olt the po sition of th e drum locking.
It m akes a clam p bolt a drum unlocking position.
Erro r
M o re th an retry tw o tim es?
No
Yes It m akes a clam p bolt a drum unlocking position.
It raises a clam p arm in th e middle position.
E rro r r eco v e ry 4
Ex1b2 It m em orizes th e d ru m present p ositio n as th e po sition w hich tail clam ps were p ut on.
It raises clam p arm
Erro r
Is tail clam ps locked up the drum?
Erro r
Disp lacem en t senso r checking.
Erro r
T he blow er o peratio n checking
Erro r
T he b alancer po siton checking
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
Ex11d
E x 1 1 b ,E x 1 1 c,E x 1 2 7 E x 1 3 b ,E x 1 5 d
Ex18c
Erro r
B alancer search
Auto balance sequence
End
E-18
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-6.Discharge Sequence E
Start
Parallel o peratio n
T ran s m o to r: It retu rn plate at th e sp eed o f 95m m /s. E rro r
It low ers trans path
It returns drum locking pin
E rro r
E x 1 0 4 ,E x1 c 2 ,E x 1 c 3 E x 1 c 4, E x 1 c5 , E x 1 cb Clutch of the discharge side is OFF.
E x19 b,Ex1 9c Parallel o peratio n
Drum : It decides on the po sition of tail clam p
It d ecides o n th e target tail clam p po sition if no t b ein g within +-2pulse and it retries
D oin g PH 5 4 senso r Plate deing?
E rro r
E x 1 1 b ,E x1 3 b E x 1 6 6 ,E x1 6 d
If it becom es the p ositio n of 150 m m to a leading clam p position, it is begun to raise a squeeze roller
E rro r
Drum : It decides on the po sition o f leading clam p
T ran s m o to r : sto p E rro r
E x11 b,Ex1 3b,E x16 6 E x 1 6 d ,E x1 7 4 E x 1 1 b ,E x1 3 b E x 1 6 5 ,E x1 6 c
Y es
No
It raises trans p ath
It d ecides o n th e target leading clam p po sition if no t b ein g within +-3 and it retries until 5times.
E rro r
T ran s m o to r : sto p Ex143 T ran s m o to r : sto p Is th ere tail clam p in the clam p arm .
Y es
E x11 b,Ex1 3b,E x16 5 E x 1 6 c, E x 1 7 3
Ex1b1
No Is it sensor o f PH 54 O FF? It m akes a clam p bo lt th e po sition o f the drum locking.
E rro r
Ex11f
No
Ex10a
It puts out the drum locking pin. It low ers clam p arm
Y es
E rro r
E x 1 9 9 ,E x1 9 a
E rro r
Servo OFF It raises clam p arm
It o pens lead ing clam ps
E rro r
E x 1 0 f, E x 1 c0 , E x 1 c1
E x 1 0 6 ,E x1 c 6 ,E x 1 c 7 It m akes a clam p bo lt th e po sition o f the drum unlocking.
E rro r Clutch of the supply side Off. Clutch of the discharge side is ON It m akes a clam p bolt po sition o f the drum locking. T ran s m o to r: It retu rn s un til PH 54 O FFs at the speed of 80m m /s.
E rro r
It raises clam p arm T ran s m o to r : sto p
Ex109 Ex11f Drum blow er OFF
It raises a clam p arm in the m id dle po sition .
T ran s m o to r: It tran sfer p l at e 1 0 m m t o PH 5 4 's O N at 48m m /s
E rro r
It low ers clam p arm Y es Is it sensor o f PH 54 O FF? It m akes a clam p bo lt th e po sition o f the drum locking.
No
No
It retried? Y es
It raises clam p arm It closes leading clam ps
E x 1 0 8 ,E x1 c 6 ,E x 1 c 7 Ex124 Is th ere tail clam p in the clam p arm ?
E rro r
Ex11d
Is there p late to w in d contin uou sly?
Y es
No Clutch of the supply side is O FF Clutch of the discharge side is OFF
It w aits 0 .5 second
It closes leading clam ps
It returns drum lockin g pin
E rro r
E rro r
E x 1 0 e, E x 1 c0 , E x 1 c1
E x19 b,Ex1 9c
E End
PT-R4300 SERVICE MANUAL
E-19
E.Reference
PT-R4000II (Ver4.0X)Sequence E rro r r ec o v ery 1
It r etu r n s p l ate t o th e side of supply plate.
E rro r r ec o v ery 3
Erro r B lower of drum is OFF
It retried?
No It op ens shu tter
Erro r
Ex110
Yes
It closes shutter
Erro r
It closes shutter
Drum : It decides on the position of squeeze
E x 1 0 2 ,E x 1 1 0 ,E x 1 4 6
It d ecides o n the target squeeze po sition if not being within +-11 and it retries.
Ex111
It raises clam p arm
Erro r
Erro r
Erro r
E x 1 1 b ,E x 1 3 b E x 1 6 7 ,E x 1 6 e
E x1 1b,E x13 b,E x 167 E x 1 6 e,E x 1 7 5
E x 1 0 5 ,E x 1 c6 ,E x 1 c7
T ran s m o to r : st o p
E rro r r ec o v ery 2 It raises niproller
Erro r
It raises trans path C lutch on the supply side is OF F
End
Ex101
It closes leading clamps
Erro r
E rro r R e co v e ry 4
It raises trans path Do sen sor of PH5 4 d etect p la te? E x 1 0 e,E x 1 c 0 ,E x 1 c 1
It raises trans path
Erro r
E x 1 0 3 ,E x 1 c2 ,E x 1 c3 E x 1 c4 ,E x 1 c 5 ,E x 1 c b
Yes
Ex142
No
It low ers tran s path
Erro r
E x 1 0 4 ,E x 1 c2 ,E x 1 c3 E x 1 c4 ,E x 1 c 5 ,E x 1 c b
B lower of drum is OFF End
T ran s m o to r : st o p E rro r r ec o v ery 2
It discharg es plate to the discharge side of pass. B lower of drum is OFF
End Do in g PH5 0 senso r, plate being?
Yes
Drum : It decides on the position of leading clamp.
Erro r
It d ecides o n the target leading clamp po sition if not being within +-3 and it retries.
It returns drum locking pin
Erro r
Ex000
E x 1 1 b ,E x 1 3 b E x 1 6 5 ,E x 1 6 c
E x1 1b,E x13 b,E x 165 E x 1 6 c,E x 1 7 3
R ecov ery o f size error
Do sen sor of PH5 0 d etect p la te?
Yes
No
Erro r
Erro r Drum : It decides on the tail clam p po sition with Ysize of 6 50 m m in the p osition . B ut it stops drum forcing wh en plate p asses PH5 0 senso r.
E x1 9b,E x19 c
E x 1 1 5 ,E x 1 1 b ,E x 1 1 c E x 1 2 7 ,E x 1 3 b
Servo OFF
It o pens lead in g clam ps
E rro r r ec o v ery 1
End
B lower of drum is OFF
Erro r
E x 1 0 f,E x 1 c 0 ,E x 1 c 1
Drum : It decides on the tail clam p po sition with th e Ysize which calculated fro m th e p o siti o n o f P H 5 0 senso r OF F in the positio n.
Erro r
E x1 1b,E x11 c E x 1 2 7 ,E x 1 3 b
It closes shutter
E rro r r ec o v ery 4
End
E-20
PT-R4300 SERVICE MANUAL
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-7.Drum high speed rotating sequence The acceleration
Deceleration
It waits in the stability tim e of 0.5 seconds
T u rn S to p co m m an d
Erro r T he all kind checking (* 1)
E x 1 4 c,E x 1 4 e ,E x 1 5 f E x 1 6 1 ,E x 1 6 2 ,E x 1 6 4 Ex18c
It w aits for the sp eed agreement signal and the speed Zero signal to ON. T he tim e out is 1 5 seco nds.
Drum h ig h speed rotation error latch signal clear.
Erro r
Erro r
E x 1 4 c,E x 1 4 e ,E x 1 5 f E x 1 6 1 ,E x 1 6 2 ,E x 1 6 4 Ex18c
Yes
E x 1 5 f,E x 1 6 4 ,E x 1 8 8 E x 1 a3 ,E x 1 a 4
T he all kind checking (* 1) It waits 1secon d Erro r
Vaccum pressure checking
Ex186
B it2,5 of address 05h are ON No
Loose plate checking is enable Vaccum pressure checking is enable
It w aits for the sp eed agreement signal and the speed Zero signal to ON. T he tim e out is 1 5 seco nds.
It sets sp eed loop gain and In te g ra tio n c o n stan t t o high speed rotational mode
Start com mand of drum high speed ro tatio n
It clears drum high speed rotation error latch sign al
Erro r
L oo se plate latch sig nal ch eck E r r o r Loose plate latch signal disable
It waits 2seconds
Ex15e
*2 T he vaccum pressure decline latch signal checking Vaccum pressure checking disable
Erro r T he all kind checking (* 1)
Erro r Ex188
*3 T h e E rr o r o f st o p p ed tim eou t
Yes B it4 of address fc00h is ON
Erro r Ex183
Ex180
No It clears SVC mode, a distance, a speed register
Yes Speed OK? No It waits until it reaches specification speed.
It m ak es speed loo p gain, In te g ra tio n c o n stan t t o generally m od e.
Erro r
*2
End
Erro r T he all kind checking (* 1)
*3
Yes B it4 of address fc00h is ON
Ex181
No
It waits 1 second until the turn is stable.
Erro r
*2
Erro r T he all kind checking (* 1)
*3
Yes B it4 of address fc00h is ON
Ex180
No B it2 of address fc00h is OF F
*1 Serv o sto p (L S5 8-1,-2, S W 58) C ov er interlock (L S 57-1,-2 ,-3 ) A ctu a ter (P H 2 0 ,P H 1 1 -2 A ,P H 1 1 - 2 H ,P H 3 0 ,P H 3 0 H ) Drum blower (INVAL M )
*2
*3
Drum sto p
Drum sto p
E x 1 5 e,E x 1 8 4 ,E x 1 8 5 E x 1 8 8 ,E x 1 a3 ,E x 1 a4
E x 1 4 c ,E x 1 4 e ,E x 1 5 f E x 1 6 1 ,E x 1 6 2 ,E x 1 6 4 Ex18c
Yes Ex181
No End
PT-R4300 SERVICE MANUAL
E-21
E.Reference
PT-R4000II (Ver4.0X)Sequence
2-8.Auto Balance Sequence
B alancer m ov em en t processing
Start
It calcu lates the po sition of balancer fro m plate size and thickness.
Yes T h e m o v em en t d ista n ce o f balancer w hich m o ves to the 1st is within 3pulse? No
It fixes th e order and the po sition wh ich m oves balancers (Home side)
T h e m o v em en t d ista n ce o f balancer w hich m o ves to the 1st is within 3pulse?
Erro r
E x1 1b,E x13 b,E x 168 E x 1 6 f,E x 1 7 6
Erro r
W h en bum p in g b y the balancer m o vem ent, it m o v es o n e to t h e te m p o r ary p o sit io n .
Detection o f balan cer
E x 1 2 0 ,E x 1 9 d
B alancer search Erro r It puts out balancer pin
Yes B alancer m ov em en t processing (H om e Side)
Erro r
E x 1 9 9 ,E x 1 9 a
E x1 20 an d less than retry two tim es? Erro r It m oves 1 st balan cer
No
E x 1 1 b ,E x 1 3 b E x 1 6 9 ,E x 1 7 0
Servo OFF Erro r It returns balancer pins.
E x1 9b,E x19 c
Erro r Detection o f balan cer
It fixes th e order and the po sition wh ich m oves balancers (Away side)
It renews the present drum Po sition as the positio n of balancer.
W h en bum p in g b y the balancer m o vem ent, it m o v es o n e to t h e te m p o r ary p o sit io n .
B alancer search Yes
B alancer m ov em en t processing (Away side)
E x 1 2 1 ,E x 1 9 e
Erro r
Ex19d and less than two times. No
Servo OFF
Yes T h e m o v em en t d ista n ce o f balanser which m oves to the 2nd is within 3pulse? No It d oes the 1 processing
End
End
E-22
PT-R4300 SERVICE MANUAL
E.Reference 3. Part names and sensor positions 3-1. Front side of Main unit PT-R4300 PH56 M55
LS57-2
M58
PH58 S0
PH55 PH11-2A
M11A
PH10A
PH10H
M11H
M41 ENC1 M2
PH11-1A
M1
LS4A
ENC1 LS4A LS4H LS56 LS57-2 M1 M2 M11A M11H M41 M55 M58 P1 PH2 PH10A PH10H PH11-1A PH11-2A PH55 PH56 PH58 S0
PT-R4300 SERVICE MANUAL
P1
PH2
LS4H
: Rotary encoder : Scanning end point limiter : Scanning start point limiter : Operation door interlock switch : Front cover interlock switch : AC servomotor : Scanning pulse motor : Balancer drive motor (Away) : Balancer drive motor (Home) : Vacuum pump : DC motor for raising/lowering the transport path : Motor for operation door : Drum vacuum pressure sensor : Scanning origin sensor : Balancer weight detection sensor (Away) : Balancer weight detection sensor (Home) : Balancer pin position detection sensor : Balancer pin sensor : Transport path change lower limit sensor : Transport path change upper limit sensor : Motor for Open/Close the operation door : Power switch
E-23
E.Reference
PT-R4000/PT-R4000II PH56 M55
LS56
LS57-2
SL58
LS57-3 PH55 M11A
PH10A
PH10H
PH11-2A
M11H
M41
ENC1 M2
M1
PH11-1A
LS4A
ENC1 LS4A LS4H LS56 LS57-2 LS57-3 M1 M2 M11A M11H M41 M55 P1 PH2 PH10A PH10H PH11-1A PH11-2A PH55 PH56 SL58
E-24
P1
PH2
LS4H
: Rotary encoder : Scanning end point limiter : Scanning start point limiter : Operation door interlock switch : Front cover interlock switch : Right side cover interlock switch : AC servomotor : Scanning pulse motor : Balancer drive motor (Away) : Balancer drive motor (Home) : Vacuum pump : DC motor for raising/lowering the transport path : Drum vacuum pressure sensor : Scanning origin sensor : Balancer weight detection sensor (Away) : Balancer weight detection sensor (Home) : Balancer pin position detection sensor : Balancer pin sensor : Transport path change lower limit sensor : Transport path change upper limit sensor : Operation door solenoid
PT-R4300 SERVICE MANUAL
E.Reference 3-2. Back side of Main unit PT-R4300
LS58-2
LS58-1 LS57-1 KA40 PH30A
PH30H
XT2 M30H
M30A KA2
PH20
PH31H
PH31A KA1
KA30MH
XT10
M20
KA1 KA2 KA30MA KA30MH KA40 LS57-1 LS58-1 LS58-2 M20 M30A M30H PH6 PH20 PH21 PH29A PH29H PH30A PH30H PH31A PH31H XT2 XT10
PT-R4300 SERVICE MANUAL
PH6
PH29H
PH29A
PH21 KA30MA BL40
: Relay for interlock power : Relay for servomotor ON/OFF power : Relay for M30A : Relay for M30H : Relay for gas suction blower ON/OFF power : Interlock switch for rear cover : Soft switch for drum slowdown : Soft switch for drum slowdown : Trailing edge clamp arm drive motor : Leading edge clamp open/close motor (Away) : Leading edge clamp open/close motor (Home) : Sensor for detecting multiple plate feeding or loose plate : Trailing edge clamp arm origin point sensor : Trailing edge clamp arm end point sensor : Plate top side detection sensor (Away) : Plate top side detection sensor (Home) : Leading edge clamp open/close origin point sensor (Away) : Leading edge clamp open/close origin point sensor (Home) : Leading edge clamp open/close end point sensor (Away) : Leading edge clamp open/close end point sensor (Home) : Terminal block : AC outlet
E-25
E.Reference PT-R4000/PT-R4000II
SL58-2
SL58-1
SL57-1 PH30H
PH30A KA40
M30H
XT2
M30A
KA2 PH31H
PH20
PH31A KA1 XT10
M20
KA1 KA2 KA40 LS57-1 LS58-1 LS58-2 M20 M30A M30H PH6 PH20 PH21 PH29A PH29H PH30A PH30H PH31A PH31H XT2 XT10
E-26
PH6
PH29H PH29A
PH21 BL40
: Relay for interlock power : Relay for servomotor ON/OFF power : Relay for gas suction blower ON/OFF power : Interlock switch for rear cover : Soft switch for drum slowdown : Soft switch for drum slowdown : Trailing edge clamp arm drive motor : Leading edge clamp open/close motor (Away) : Leading edge clamp open/close motor (Home) : Sensor for detecting multiple plate feeding or loose plate : Trailing edge clamp arm origin point sensor : Trailing edge clamp arm origin point sensor : Plate top side detection sensor (Away) : Plate top side detection sensor (Home) : Leading edge clamp open/close origin point sensor (Away) : Leading edge clamp open/close origin point sensor (Home) : Leading edge clamp open/close end point sensor (Away) : Leading edge clamp open/close end point sensor (Home) : Terminal block : AC outlet
PT-R4300 SERVICE MANUAL
E.Reference 3-3. Left side of Main unit PT-R4300 R1
U6
CON-PTR4 KA3 LS57-4 PMD61 XT3 PMD50 PMD2
U5
S1&FU1
U3
TH1
U2
FAN2
RCP
U1
FAN1
XT4
U9
BZ1 U4
LS4A SPX32 RB31 E1A PIO(The back)
BZ1 CON-PTR4(2) E1A FAN2 FU1 LS4A LS57-4 PMD2 PMD50 PMD61 R1 S1 U1 U2 U3 U4 U5 U6 U9 XT3 XT4 TH1 KA3 RCP RB31 SPX32 PIO PT-R4300 SERVICE MANUAL
: Buzzer : CON-PTR4(2) board : AC servo pack : Fan : Fuse for interlock circuits : Scanning end point limiter : Interlock switch for left side cover : Pulse motor driver (for M2 scanning motor) : Pulse motor driver (for M50 plate transport motor) : Pulse motor driver (for M61 plate side alignment motor) : Enamel resistor : Maintenance switch : Switching regulator (5V_100W) : Switching regulator (15V_75W) : Switching regulator (-15V_75W) : Switching regulator (24V_300W) : Switching regulator (24V_300W) : Switching regulator (-5V_300W) : Switching regulator (24V_30W) : Terminal block : Terminal block : Temperature sensor : Relay for operation door interlock : RCP2 board : RB31 board : SPX32 board : PIO-PTR4(2) board E-27
E.Reference PT-R4000/PT-R4000II U7 U5
CON-PTR4 XT3
PMD50 PMD61
R1 PMD2
U6
TH1
U3
FAN2
U2
RCP
FAN1
U1 U4
XT4 BZ1 LS4A
SPX32 RB31
E1A PIO(The back)
E-28
BZ1 CON-PTR4 E1A FAN2 LS4A PMD2 PMD50 PMD61 R1 U1 U2 U3 U4 U5 U6 U7 XT3 XT4 TH1
: Buzzer : CON-PTR4 board : AC servo pack : Fan : Scanning end point limiter : Pulse motor driver (for M2 scanning motor) : Pulse motor driver (for M50 plate transport motor) : Pulse motor driver (for M61 plate side alignment motor) : Enamel resistor : Switching regulator (5V_100W) : Switching regulator (15V_75W) : Switching regulator (-15V_75W) : Switching regulator (24V_300W) : Switching regulator (24V_150W) : Switching regulator (-5V_300W) : Switching regulator (24V_100W) : Terminal block : Terminal block : Temperature sensor
RCP RB31 SPX32 PIO
: RCP2 board : RB31 board : SPX32 board : PIO-PTR4 board
PT-R4300 SERVICE MANUAL
E.Reference 3-4. Rite side of Main unit PT-R4300
PANEL
SW58
LS56 PH58 M58 QF1
M11H
LS57-3
Z1 PH11-2H SRGE
PH11-1H
XT1 XT10
CAL-Sens
S0 CAL-sens ENC1 SRGE LS57-3 LS56 M1 M11H M58 PANEL PH11-1H PH11-2H PH58 QF1 SW58 XT0 XT1 Z1
PT-R4300 SERVICE MANUAL
ENC1
M1
: Main switch : Calibration sensor board : Rotary encoder : Serge protection board : Interlock switch for right side cover : Interlock switch for operation door : AC servomotor : Balancer drive motor : Motor for operation door : Touch panel : Balancer pin position detection sensor1 (Home) : Balancer pin position detection sensor2 (Home) : Motor for Open/Close the operation door : Circuit protector : Drum rotation stop switch : Terminal block (for AC input) : Terminal block (for SAL/MAL connection) : Power noise filter
E-29
E.Reference PT-R400/PT-R4000II
PANEL
SW58
LS57-3 C1
C2 M11H Z1 PH11-2H
PH11-1H
FV1 QF1 XT1
CAL-Sens
C1 C2 CAL-sens ENC1 FV1 LS57-3 M1 M11H PANEL PH11-1H PH11-2H QF1 SW58 XT1 Z1
E-30
ENC1
M1
: Capacitor : Capacitor : Calibration sensor board : Rotary encoder : Surge absorber : Interlock switch for right side cover : AC servomotor : Balancer drive motor : Touch panel : Balancer pin position detection sensor1 (Home) : Balancer pin position detection sensor2 (Home) : Circuit protector : Drum rotation stop switch : Terminal block : Power noise filter
PT-R4300 SERVICE MANUAL
E.Reference 3-5. Top side of Main unit PT-R4300
SL53
PH53
PH70
PH50
PH57
M52 PH52 PH54 PH56
PH59
M50
TH1 PH58
M55
PH51
LS56 M50 M52 M55 PH50 PH51 PH51 PH52 PH53 PH54 PH56 PH57 PH58 PH59 PH70 SL53 M58 TH1
PT-R4300 SERVICE MANUAL
M58 LS56
: Operation door interlock switch : Plate transport motor : Nip rollor drive motor : DC motor for raising/lowreing the transport path : Plate pass sensor on the plate-loading path : Sensor for detecting an interleaf on the back of the plate : Amplifier for the sensor for detecting an interleaf on the back of the plate : Nip rollor origin sensor : Shutter origin sensor : Plate pass sensor1 on the plate transport path : Transport path change upper limit sensor : Transport path punch position sensor : Motor for Open/Close the operation door : Plate pass sensor2 on the plate transport path : AT unit plate detection sensor : Rotary solenoid for shutter : Motor for operation door : Temperature sensor
E-31
E.Reference PT-R4000/PT-R4000II
SL53
PH53
PH70
PH50
PH57
LS57-3
M52 PH52 M50
PH54
PH56
TH1
M55
PH51
LS56 M50 M52 M55 PH50 PH51 PH51 PH52 PH53 PH54 PH56 PH57 PH70 SL53 TH1
E-32
LS56
SL58
: Operation door interlock switch : Plate transport motor : Nip rollor drive motor : DC motor for raising/lowreing the transport path : Plate pass sensor on the plate-loading path : Sensor for detecting an interleaf on the back of the plate : Amplifier for the sensor for detecting an interleaf on the back of the plate : Nip rollor origin sensor : Shutter origin sensor : Plate pass sensor1 on the plate transport path : Transport path change upper limit sensor : Transport path punch position sensor : AT unit plate detection sensor : Rotary solenoid for shutter : Temperature sensor
PT-R4300 SERVICE MANUAL
E.Reference 3-6. Transport unit of Main unit PT-R4300/PT-R4000/PT-R4000II
SL53
M52
SL59-2
M50
PH51
PH51
PH70
PH55 PH53
PH57
M50 M52 PH51 PH51 PH52 PH53 PH55 PH56 PH57 SL53 SL59-1 SL59-2
PT-R4300 SERVICE MANUAL
SL59-1
PH56
: Plate transport motor : Nip rollor drive motor : Sensor for detecting an interleaf on the back of the plate : Amplifier for the sensor for detecting an interleafe on the back of the plate : Nip rollor origin sensor : Shutter origin sensor : Transport path change lower limit sensor : Transport path change upper limit sensor : Transport path punch position sensor : Rotary solenoid for shutter : Transport clutch on the plate loading side : Transport clutch on the plate unloading side
E-33
E.Reference 3-7. Plate side alignment of Main unit PT-R4300/PT-R4000/PT-R4000II
PH61A
PH61H
PH62
M61 PH61A PH61H PH62 PH63
M61
PH63
: Plate side alignment drive motor : Sensor for detecting the Away side edge of a plate for side alignment : Sensor for detecting the Home side edge of a plate for side alignment : Plate edge detection sensor for the punch unit : Side alignment origin sensor
3-8. Clamp arm unit of Main unit PT-R4300/PT-R4000/PT-R4000II
PH24-1
PH27-1
PH24-1 PH24-2 PH27-1 PH27-2 PH27-3 M24
E-34
PH27-2
M24
PH27-3
PH24-2
: Trailing edge clamp open/close position sensor : Trailing edge clamp open/close position sensor : Trailing edge clamp presence detection sensor : Trailing edge clamp presence detection sensor : Trailing edge clamp presence detection sensor : Trailing edge clamp hook drive motor
PT-R4300 SERVICE MANUAL
E.Reference 3-9. Recording Head Unit PT-R4300/PT-R4000/PT-R4000II
Focus motor driver Parabolic mirror PM80 LS80
Zoom lens
PM81 Dew condensation sensor Cylindrical lens
Temperature sensor
Stereographic projection lens No.1 Lens Reflective mirror
Fan for Peltier element Cooler for Peltier element
LD block PH84 Stereographic projection lens
Parabolic mirror
Fainal lens PH86 PH85 PH82
PH83
Focus motor driver
PT-R4300 SERVICE MANUAL
E-35
E.Reference 3-10. RCP2 board (PT-R4300/PT-R4000/PT-R4000II)
X 166
X 163
X 162
X 161
X 150 X 160
U4
X 159
U13
U14
X 158
TEST
U15
R O M fo r d e b u g in g
X 157
U18
X 156
X 155
CPU
D IP S W 1 X 154 OFF ON
H L 1 -8
1
H L 9 -1 6
U62 X 153
8
H L 1 7 -2 4
RESET
H L 2 5 -3 2 ALTERA X 164 PLL
H L 3 3 -4 0
X 167 X 151
H L 4 1 -4 2
X 152
H L 4 3 -5 1
Connectors marked with tint
E-36
are not used.
PT-R4300 SERVICE MANUAL
E.Reference U4 U13 U14 U15 U18 X150 X151 X152 X153 X154 X155 X156 X157 X158 X159 X160 X161 X162 X163 X164 X166 X167 RESET
: Program ROM (flash memory) : Program ROM (flash memory) : NV RAM (to write data for exposure conditions, error logs and timer settings) : User data, individual machine data (flash memory) : User data, individual machine data (flash memory) : Power supply (+5V, -5V) : I/F with the PIO-CTP board : I/F with the RB31 board : Secondary scanning motor’s control signal : I/F with the operation panel : Not used : PIF (RS-232C) : I/F (RS-232C) with the primary scanning motor : I/F (RS-232C) with the optical head : I/F (RS-232C) for remote maintenance : Not used : Temperature sensor (for machine interior) : AT unit : Not used (RS-232C) : Not used :Not used : Not used : Reset switch
DIPSW1
: No.1 :Validates the command input from the terminals. (However, this setting prevents the PT-R4XXX from communicating with the downloader and the remote maintenance PC.) No.7: Prevents updating of the machine setting data when the software version is updated. No.8: Allows the PT-R4XXX to start up in the Boot mode. (In this mode, only firmware downloading can be performed.)
TEST
: Short Open
PT-R4300 SERVICE MANUAL
The ROM for debugging is used. The Flash ROM is used.
E-37
E.Reference 3-11. RB31 board (PT-R4300/PT-R4000/PT-R4000II)
X 105
X 101
X 100 X 102
Test pattern generation circuit X 106 3P 6P 1P
Interlace control ROM
Test pattern ROM
X 103
7H
SW 1
H L 1 -5 0
Connectors marked with tint X100 X101 X102 X103 X105 X106 SW1 E-38
are not used.
: Power supply (+5V) : I/F with the RCP board : I/F with the PIF : Beam output to the recording head : I/F with the SPX32 : Not used : Reset switch PT-R4300 SERVICE MANUAL
E.Reference 3-12. SPX32 board (PT-R4300/PT-R4000/PT-R4000II)
X 107
5D
2D
L E D 1 -2 7
Connectors marked with tint
PT-R4300 SERVICE MANUAL
are not used.
E-39
E.Reference 3-13. PIO-PTR4(2) board (PT-R4300)
X 111
X 112
TP1 X 110 TP3
TP2 TP4 TP5 TP6 X 122
X 113 TP7
TP9
TP8
T P 10 X 114
T P 11
T P 14
X 116
T P 18 X 125
T P 15
U32
T P 19 X 115 1 2
ALTERA T P 20
X 118
J2
T P 21 T P 22
T P 24 LED1 19 20
T P 25 T P 26 T P 27
ALTERA LED7 LED8
T P 28
T P 30
T P 34
X 120
X 117
T P 33 T P 32
T P 31
X 119
VR1
Connectors marked with tint
E-40
X 124
are not used.
PT-R4300 SERVICE MANUAL
E.Reference
X110 X111 X112 X113 X114 X115 X116 X117 X118 X119 X120 X122 X124 X125 U32
: Power supply (+5V, +5VE, +-15V, +-15VE, +24V, +24VE) : I/F with the RCP board : Secondary scanning motor’s control signal : Input signal (PH58, PH59, S1) : I/F with the CON-PTR4 board : Not used (for the auto loader) : For debugging : Primary scanning motor positioning signal output : Test pin for debugging : I/F for controlling the primary scanning motor : Encoder input : Blower vacuum pressure sensor input (digital signal) : Loose plate detection sensor input (analog signal) : Servo pack power supply (for the primary scanning motor) ON output : Program ROM for hardware
PT-R4300 SERVICE MANUAL
E-41
E.Reference
PIO-PTR4 board (PT-R4000/PT-R4000II)
X 111
X 112
TP1 X 110 TP3
TP2 TP4 TP5 TP6 X 122 TP7
TP9
TP8
T P 10 X 114
T P 11
T P 14 X 116
T P 18 X 125
T P 15
U32
T P 19 X 115 1 2
ALTERA T P 20
X 118
J2
T P 21 T P 22
T P 24 LED1 19 20
T P 25 T P 26 T P 27
ALTERA
LED7 LED8
T P 28
T P 30
T P 34
X 120
X 117
T P 33 T P 32
T P 31
X 119
VR1
Connectors marked with tint
E-42
X 124
are not used.
PT-R4300 SERVICE MANUAL
E.Reference
X110 X111 X112 X114 X115 X116 X117 X118 X119 X120 X122 X124 X125 U32
: power supply (+5V, +5VE, +-15V, +-15VE, +24V, +24VE) : I/F with the RCP board : Secondary scanning motor’s control signal : I/F with the CON-PTR4 board : Not used (for the auto loader) : For debugging : Primary scanning motor positioning signal output : Test pin for debugging : I/F for controlling the primary scanning motor : Encoder input : Blower vacuum pressure sensor input (digital signal) : Loose plate detection sensor input (analog signal) : Servo pack power supply (for the primary scanning motor) ON output : Program ROM for hardware
PT-R4300 SERVICE MANUAL
E-43
E.Reference 3-14. CON-PTR4 board (PT-R4300/PT-R4000/PT-R4000II)
LED2A LED4A LED6A LED8A LED10A LED7H LED14A LED16A LED14H LED20A LED22A LED2H LED4H LED16H LED30A LED32A LED34A LED30H LED32H LED42A LED44H LED24H LED26H LED24A
TP2
LED1A LED3H LED5A LED7A LED9A LED11A LED13A LED15A LED13H LED19A LED21A LED1H LED3A LED15H LED29A LED31A LED33A LED29H LED17H LED21H LED43A LED23H LED25H LED23A
X23
TP5
TP3 TP6 TP7 TP8 TP9
FU10
JP3
FU2 FU9
C07
C04 CB1
C06
FU11 C02
C03
C05 CO9 C08
TP4 CP1
CA4 JP1 JP2 CA1
CH1
CA2
CA3 CS1
X11 CP2
TP1
Connectors marked with tint
E-44
are not used.
PT-R4300 SERVICE MANUAL
E.Reference CA1 CA2 CA3 CA4 CH1 CS1 CP1 CP2 CB1 CO1 CO2 CO3 CO47 CO5 CO6 CO7 CO8 CO9 FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10
FU11
LED1A LED1H LED2A LED2H LED3A LED3H LED4A LED4H LED5A LED6A
: PH11-1A, PH11-2A, PH10A, PH30A, PH31A, PH21, PH24-1, PH24-2, PH27-1, PH27-2, PH27-3 : PH56, PH57, PH61A, PH61H, PH63, PH62, PH70 : PH50, PH52, PH54, PH53, PH55 : PH29A, PH29H, PH51, LS28-1 to LS28-6, PD_READY, PD_ERROR, AT-ON : PH11-1H, PH11-2H, PH10H, PH20, PH30H, PH31H, LS4H, LS4A, PH2 : LS57-1, LS57-2, LS57-3, LS58-1, LS58-2, SW58 : M60-1, M60-2, M60-3, M60-4, M60-5, M60-6 : SB60-1, SB60-2, SB60-3, SB60-4, SB60-5, SB60-6 : Drum suction blower ON/OFF, Inverter reset, Inverter alarm (INVALM) Fan for the inverter (spare) : M11A, M20, M30A, M24, M11H, M30H : M52, SL53, SL59-1, SL59-2, SL58 : Blower pump, Alarm buzzer, Gas suction blower : M50 : M61 : M2 : M55 : Not used : Not used : Nip rollor drive motor M52 : Balancer drive motor (Away) M11A : Trailing edge clamp arm drive motor M20 : Leading edge clamp open/close motor (Away) M30A : Trailing edge clamp hook drive motor M24 : Balancer drive motor (Home) M11H : Leading edge clamp open/close motor (Home) M30H : Motor for operation door M58 (PT-R4300) : DC motor for raising/lowreing the transport path M55 : Solenoid for transport unit Rotary solenoid for shutter SL53 Transport clutch on the plate loading side SL59-1 Transport clutch on the plate unloading side SL59-2 Operation door solenoid SL58 (PT-R4000/PT-R4000II) : Vacuum pump M41 “An automatic return type over-current protection element” : PH11-1A (Balancer pin position detection sensor 1 (Away)) : PH11-1H (Balancer pin position detection sensor 1 (Home)) : PH11-2A (Balancer pin sensor 2 (Away)) : PH11-2H (Balancer pin sensor 2 (Home)) : Processor ready (PD_READY) : PH20 (Trailing edge clamp arm origin sensor : PH21 (Trailing edge clamp arm end point sensor) : Processor error (PD_ERROR) : PH24-1 (Trailing edge clamp open/close position sensor 1) : PH24-2 (Trailing edge clamp open/close position sensor 2)
PT-R4300 SERVICE MANUAL
E-45
E.Reference LED7A LED7H LED8A LED9A LED10A LED11A LED13A LED13H LED14A LED14H LED15A LED15H LED16A LED16H LED17H LED19A LED20A LED21A LED21H LED22A LED22H LED23A LED23H LED24A LED24H LED25H LED26H LED29A LED29H LED30A LED30H LED31A LED32A LED33A LED34A LED42A LED43A LED44A
E-46
: PH10A (Balancer weight detection sensor (Away)) : PH10H (Balancer weight detection sensor (Home)) : LS28-1 to LS28-6 (Hook lever switch) (PT-R4000 S/N35 or lower) : PH27-1 (Trailing edge clamp presence detection sensor 1) : PH27-2 (Trailing edge clamp presence detection sensor 2) : PH27-3 (Trailing edge clamp presence detection sensor 3) : PH30A (Leading edge clamp open/close origin sensor (Away)) : PH30H (Leading edge clamp open/close origin sensor (Home)) : PH31A (Leading edge clamp open/close end point sensor (Away)) : PH31H (Leading edge clamp open/close end point sensor (Home)) : PH50 (Plate pass sensor on the plate-loading path) : LS4H (Scanning start point limiter) : PH52 (Nip rollor origin sensor) : LS4A (Scanning end point limiter) : PH2 (Scanning origin sensor) : PH54 (Plate pass sensor on the plate transport path) : PH53 (Shutter origin sensor) : PH55 (Transport path change lower limit sensor) : PH51 (Sensor for detecting an interleaf on the back of the plate) : PH56 (Transport path change upper limit sensor) : Reserve input : SB60-5 (Punch 5 origin sensor) : SB60-1 (Punch 1 origin sensor) : SB60-6 (Punch 6 origin sensor) : SB60-2 (Punch 2 origin sensor) : SB60-3 (Punch 3 origin sensor) : SB60-4 (Punch 4 origin sensor) : PH61A (Sensor for detecting the Away side edge of a plate for side alignment) : PH61H (Sensor for detecting the Home side edge of a plate for side alignment) : PH63 (Side alignment origin sensor) : PH62 (Plate edge detection sensor for the punch unit) : PH70 (AT unit plate detection sensor) : LS56 (Operation door interlock switch) : Operation door interlock switch : Operation door interlock switch : PH57 (Transport path punch position sensor) : PH29A (Plate top side detection sensor (Away)) : PH29H (Plate top side detection sensor (Home))
PT-R4300 SERVICE MANUAL
E.Reference 3-15. Laser Head CPU board (PT-R4300, PT-R4000, PT-R4000II)
X 820
X 819
+15V AG N D
24G A +24VB -5 V
24G B
X 813
X 811
-1 5 V
X 812
X 815
X 814
X 810
+24VA
DGND -5 V G J P 1 -7
+5V
DSW 1
CLK1
CLK2 ALTERA
U2 VR2 VR1
SW 1
HL2 HL1
U2
: DATA ROM
X810 X811 X812 X813 X814 X815 X819 X820 SW1 VR1 VR2
: Image data from the RB31 board : RS232C for command communication : Calibration sensor input : Laser diode block sensor input (from the laser head relay board) : Focus motor drive output : Zoom motor drive output : Mother board connection : Mother board connection : CPU reset switch : For the temperature sensor input adjustment (Resolution) : For the temperature sensor input adjustment (Offset values)
JP1 JP2 JP3 JP4 JP5 JP6 JP7
: Switches the methods for resetting the CPU : Switches the methods for command communication : Switches the methods for command communication : Switches the methods for command communication : Switches the methods for command communication : Switches the methods for command communication : Switches the methods for command communication
PT-R4300 SERVICE MANUAL
E-47
E.Reference 3-16. Laser Head Driver board (PT-R4300/PT-R4000/PT-R4000II)
X 832
X 833 AGND
+24G P
DGND +5V
+15V
-1 5 V
-5 V G
-5 V
+24V
X 831 VR2 VR1
X 830
X830 X831 X832 X833
: LD drive signal output : Peltier element control signal connection : Mother ba\oard connection : Mother ba\oard connection
VR1 : For adjusting the Peltier element’s control voltage to 0V VR2 : For adjusting the Peltier element’s control voltage to it’s maximum value Drive board and it’s supporting LD channels Driver board 1 :26, 19, 12, 05, 06, 13, 20, 27 Driver board 2 :28, 21, 14, 07, 00, 15, 22, 29 Driver board 3 :08, 01, 30, 23, 16, 09, 02, 31 Driver board 4 :24, 17, 10, 03, 04, 11, 18, 25 (The driver boards are numbered 1, 2, 3 and 4, from the one closest to the CPU board)
E-48
PT-R4300 SERVICE MANUAL
E.Reference 3-17. Laser Head Mother board (PT-R4300/PT-R4000/PT-R4000II)
X 808
X 801 X 802 X 803
X 807
X 819
X 800 X 806
X 804 X 805
X 820
X 8 3 2 -1
X 8 3 3 -1
X 8 3 2 -2
X 8 3 3 -2
X 8 3 2 -3
X 8 3 3 -3
X 8 3 2 -4
X 8 3 3 -4
X800 : LD drive power supply (-5V) X801 : Power supply input for substrate control X802 : Cooler fan’s power supply for Peltier element X803 X804 X805 X806 X807 X808
: Fan power supply (for cooling the driver board) : Fan power supply (for cooling the driver board) (Not used) : Fan power supply (for cooling the driver board) : Head cover switch input : Power supply control output for LD drive : Power supply input for a peltier drive
X819_X820 X832-1_X833-1 X832-2_X833-2 X832-3_X833-3 X832-4_X833-4
PT-R4300 SERVICE MANUAL
: For CPU board : For driver 1 board : For driver 2 board : For driver 3 board : For driver 4 board
E-49
E.Reference 3-18. Laser Head Relay board (PT-R4300/PT-R4000/PT-r4000II)
LD 1 X 840 X 844
X 849
X 843
X 842
X 841
TH1 X 845
XCH04 XCH11
XCH03 XCH10
X 847
X 848
XCH18 XCH25
XCH17 XCH24 XCH31
XCH02 XCH09 XCH16 XCH23 XCH30
XCH01 XCH08 XCH15 XCH22 XCH29
XCH00 XCH07
XCH14 XCH21 XCH28
XCH06 XCH13 XCH20 XCH27
XCH05
E-50
XCH12 XCH19 XCH26
PT-R4300 SERVICE MANUAL
E.Reference
X841 X842 X843 X844 X840 X849 LD1
: LD drive signal 1 input : LD drive signal 2 input : LD drive signal 3 input : LD drive signal 4 input : Sensor signal output (to CPU) : Socket for inserting the short-circuit connector to prevent static electricity : -5V power supply monitor
X845 X847 X848 TH1
: Temperature sensor input for the LD block : Sensor input for detecting tha Fin temperature on the Peltier unit : Sensor input for detecting dew condensation in the LD block : Temperature sensor
XCH00 to XCH31 : LD (laser diode) channels
PT-R4300 SERVICE MANUAL
E-51
E.Reference 3-19. Laser Diode Array Block (PT-R4300/PT-R4000/PT-R4000II)
Ch11 Ch4
Ch25 Ch18
Ch31
Ch0
Ch5
Ch19 Ch12
E-52
Ch26
PT-R4300 SERVICE MANUAL
E.Reference
4. Maintenance software RMLight4 4-1.Outline The RMLight4 maintenance software is installed in the following machines to perform data downloading and uploading. *PT-R8000 *PT-R8000II *PT-R8600 *PT-R4000 *PT-R4000II *PT-R4300
The RMLight maintenance software that has been used for the PT-R8000 and PT-R4000 cannot be used with the PT-R8600, PT-R8000II, PT-R4000 (Ver. 4.00 or later), PT-R4000II, or PT-R4300.
4-2.Requirements 1) Terminal Terminal environment OS: Windows 95 or Windows 98 2) Cable Cable specification Specification : RS232C straight cable (Normal) Model Connection
: D-sub9P plug, D-sub9P plug : All
3) RMLight4 maintenance software for PT-R RMLight4.exe, RMLight.cfg CATION! The RMLight.cfg file is a cfg file for RMLight4 and is prepared for each machine type. When using the RMLight.cfg file for another machine type, change the contents of the file as noted below. [ID] Product="PT-RXXXX" Vendor="SCREEN" Protectcode="SUPERSONIC" For PT-R4000 Product = “PT-R4000” For PT-R4000II Product = “PT-R4000” For PT-R4300 Product = “PT-R4300” PT-R4300 SERVICE MANUAL
For PT-R8000 Product = “PT-R8000” For PT-R8000II Product = “PT-R8600” For PT-R8600 Product = “PT-R8600” E-53
E.Reference 4-3.Terminal setting Terminal setting is not necessary as it is set automatically.
4-4.Installation of RMLight4 1) Prepare the following two files. (Total: 49 kbyte) RMLight4.exe, RMLight.cfg CATION! The RMLight.cfg file is a cfg file for RMLight4. 2) Save the above two files in the same directory on the terminal.
4-5.Connecting the terminal to the main unit 1) Connect the communication cable to the communication port of the terminal. 2) Connect the communication cable to the “PC” port, which is circled in the figure below.
Rear side of the main unit(PT-R4XXX)
E-54
PT-R4300 SERVICE MANUAL
E.Reference 4-6.Procedure for downloading the PT-R firmware CATION! 1. Confirm that all DIP switches on the RCP board are off. 2. When the panel data is also downloaded at the same time, first download the panel data. 3. Be sure to perform downloading while the main unit panel displays the following screen, which appears immediately after the power is supplied to the main unit. 0101
P T- R 4 X X X Please press [START]
START
'01.05.01 V1.00
1) Prepare the following PT-R4XXX firmware files. There are two files for the PT-R4300 and PT-R4000II and one file for the PT-R4000. For PT-R4300 (Ver. 1.00, As of May 7, 2002) F43_100.dat: Main firmware S43_100.dat: Messages For PT-R4000II (Ver. 4.03, As of April 4, 2002) Fir4_403.dat: Main firmware Str4_403.dat: Messages For PT-R4000 (Ver. 3.05, As of April 4, 2002) Fir4_305.dat: Main firmware 2) Execute RMLight4.exe. The window shown in step 3 appears.
3) Upload UserData and MachData by referring to ”8-2 Procedure for data upload”.
PT-R4300 SERVICE MANUAL
E-55
E.Reference 4) After UserData and MachData have been uploaded, click Download in the window below.
5) Select the data to be downloaded and click the Open button. The window shown in step 6 appears.
The figure above is an example of the PT-R4300 Ver. 1.00. As mentioned earlier, there are two firmware files for the PT-R4000 (Ver. 4.00 or later) and the PT-R4000II. You can install either file first. The PT-R4000 requires one file only. 6) Click OK to start downloading of the selected data.
During downloading, the following window is displayed.
E-56
PT-R4300 SERVICE MANUAL
E.Reference The following screen is displayed in the main unit panel during downloading.
7) When the data has been downloaded, the following window appears. Click OK to display the window shown in step 8.
PT-R4300 Ver. 1.00 F43_100.dat (Approx. 12 min.) S43_100.dat (Approx. 3 min.) 8) When the following window appears, turn the power supply to the main unit off and then on again.
9) For the PT-R4000 (Ver. 4.00 or later) and the PT-R4000II, download the other file by following from step 4 onwards. Download for the PT-R4000 has been completed.
10) Download UserData and MachData that were uploaded in step 3 as necessary by referring to “4-8-3 Procedure for data download”.
PT-R4300 SERVICE MANUAL
E-57
E.Reference 4-7.Procedure for downloading the PT-R panel data CATION!
1. Confirm that all DIP switches on the RCP board are off. 2. When the panel data is also downloaded at the same time, first download the panel data. 3. Be sure to perform downloading while the main unit panel displays the following screen, which appears immediately after the power is supplied to the main unit. 0101
P T- R 4 X X X Please press [START]
START
'01.05.01 V1.00
1) Prepare the following file for the PT-R panel data. For PT-R4000 (Ver. 4.00, As of May 7, 2002) PanelDif_v506_v500.dat 2) Execute RMLight4.exe. The window shown in step 3 appears.
3) Click Download in the window below. The window shown in step 4 appears.
E-58
PT-R4300 SERVICE MANUAL
E.Reference 4) Select the data to be downloaded and click the Open button. The window shown in step 5 appears.
The figure above is an example of the PT-R4000 Ver. 3.01.
5) Click OK to start downloading of the selected data.
During downloading, the following window is displayed.
The following screen is displayed in the main unit panel during downloading.
PT-R4300 SERVICE MANUAL
E-59
E.Reference 6) When the data has been downloaded, the following window appears. Click OK to display the window shown in step 7.
Download time PT-R4000 Ver. 3.01: Approx. 4 min. 7) When the following window appears, turn the power supply to the main unit off and then on again.
E-60
PT-R4300 SERVICE MANUAL
E.Reference 4-8.Uploading or downloading the PT-R’s machine specific value data 4-8-1.Data types that can be uploaded or downloaded Exposure condition settings, error logs, and consumable timer data cannot be uploaded. CATION! The NV RAM data (exposure conditions, error logs, and consumables timer) cannot be uploaded. To transfer the NV RAM data, refer to page C-72. 1) UserData User data · Printing machine setting (1 to 15) · Plate setting (1 to 15) · Plate type setting (1 to 15, 30 to 45) · Punch data (punch name and “Set punch data” setting in the Service Maintenance screen) 2) MachData The data saved in the following menus of the Service Maintenance screen. · Initialize data / Select brand · Machine option select · Input parameter / Set Correction data · Input parameter / Drum base position · Input parameter / Punch adjust · Input parameter / Calibration position · Input parameter / Set misc. data · Input parameter / Set resolution · Input parameter / Set weight · Input parameter / RH parameter / Auto calibration 3) HeadData A binary file that is composed of the three data types (HeadData_CPU, HeadData_DRV1, and HeadData_DRV2) described in 4, 5, and 6 below. The recording head data of the PT-R4300, PT-R4000, PT-R4000II, PT-R8000, or PT-R8000II are saved in HeadData. Only the PT-R8600 can save each datum individually.
PT-R4300 SERVICE MANUAL
E-61
E.Reference 7) LogList A list of the dates and times when the sequence log data Log 0 to Log 23 described in 8 below are obtained. A sample LogList is shown below. 0 08/28 08:47:00 1 08/27 16:21:01 2 08/27 16:13:51 3 08/27 15:00:42 4 08/27 14:09:34 5 08/27 13:45:45 6 08/27 12:18:03 7 08/24 15:46:00 8 08/23 17:19:00 9 32767 byte 10 08/23 16:44:17 11 empty 12 empty 13 32767 byte 14 08/23 15:41:00 15 08/23 13:51:00 16 08/23 09:52:00 17 08/23 08:54:00 18 32767 byte 19 08/22 13:22:00 20 08/17 10:53:27 21 08/17 10:14:58 22 08/16 18:16:21 23 empty
8) Log 0 to Log 23 Sequence log data. A maximum of 23 log data can be stored in the PT-R’s memory. Note that the size of each log data is 33 kbyte.
E-62
PT-R4300 SERVICE MANUAL
E.Reference 4-8-2.Procedure for data upload CATION! 1. Confirm that all DIP switches on the RCP board are off. 2. Be sure to perform uploading while the main unit panel displays the following screen, which appears immediately after the power is supplied to the main unit. 0101
P T- R 4 X X X Please press [START]
START
'01.05.01 V1.00
1) Execute RMLight4.exe. The window shown in step 2 appears.
2)
Click Upload in the window below. The window shown in step 3 appears.
3) Select the data to be uploaded in the following window and click OK. For data types, refer to the previous section (8-1). The window shown in step 4 appears.
PT-R4300 SERVICE MANUAL
E-63
E.Reference 4) Select the directory in which the data is to be saved, enter the file name, and then click the Save button. The window shown in step 5 appears.
Default file name: “type of data”_“date”.dat The sample window above is displayed when UserData is uploaded. 5) Click OK in the following window to start uploading of the data.
During uploading, the following window is displayed.
The following screen is displayed in the main unit panel during uploading.
E-64
PT-R4300 SERVICE MANUAL
E.Reference 6) When the data has been uploaded, the following window appears.
Upload time of each data - UserData: Approx. 1.5 min. - MachData: Approx. 30 sec. - HeadData: Approx. 2.5 min. - LogList: Approx. 10 sec. - Log 0 to Log 23: Approx. 1 min. for each For PT-R8600 only -HeadData_CPU: Approx. 1 min. -HeadData_DRV1: Approx. 1 min. -HeadData_DRV2: Approx. 1 min. CATION! Do not rewrite or change the uploaded files. When a file is downloaded, RMLight checks the file and confirms the type of data, then automatically determines where to save the data.
PT-R4300 SERVICE MANUAL
E-65
E.Reference 4-8-3.Procedure for data download CATION! 1. Confirm that all DIP switches on the RCP board are off. 2. Be sure to perform uploading while the main unit panel displays the following screen, which appears immediately after the power is supplied to the main unit. 0101
P T- R 4 X X X Please press [START]
START
'01.05.01 V1.00
3. Do not rewrite or change the uploaded files. When a file is downloaded, RMLight checks the file and confirms the type of data, then automatically determines where to save the data. 1) Execute RMLight4.exe. The window shown in step 2 appears.
2) Click Download in the window below. The window shown in step 3 appears.
E-66
PT-R4300 SERVICE MANUAL
E.Reference 3) Select the data to be downloaded and click the Open button. The window shown in step 4 appears.
The sample window above is displayed when UserData is downloaded. 4) Click OK to start downloading.
During downloading, the following window is displayed.
The following screen is displayed in the main unit panel during downloading.
PT-R4300 SERVICE MANUAL
E-67
E.Reference 5) When the data has been downloaded, the following window appears. Click OK to display the window shown in step 7.
- UserData: Approx. 1.5 min. - MachData: Approx. 30 sec. - HeadData: Approx. 2.5 min. For PT-R8600 only -HeadData_CPU: Approx. 2 min. -HeadData_DRV1: Approx. 30 sec. -HeadData_DRV2: Approx. 30 sec. 6) When the following window appears, turn the power supply to the main unit off and then on again.
E-68
PT-R4300 SERVICE MANUAL
0 .5 A S1
L S 5 7 -1
LS56
U 9 (2 4 V /3 0 W ) XT0
L S 5 7 -2 L S 5 7 -3
L D D rive r
L S 5 7 -4
U 6 (5 V /3 0 0 W ) M a in S w itc h
RC
S1
KA1
S0
H ead CPU
S u rg e P ro te c to r B o a rd
SRGE
E 1A U 4 (2 4 V /3 0 0 W )
24V
H ead S e n s o r,L im it S w itc h ,P a n e l Fan
XT1
U 5 (2 4 V /3 0 0 W )
A c tu a to r
U 3 (1 5 V /7 5 W )
C irc u it P ro te c to r QF1
-1 5 V
15 A
15 A
KA3 P IO ,T e m p e ra tu re s e n s o r
KA1
U 2 (1 5 V /7 5 W )
+15V
N o is e F iltte r Z1
5V
R C P 2 ,R B 3 1 ,P IO
U 1 (5 V /1 0 0 W ) 5V
C O N ,H e a d C P U
E.Reference
L S 5 7 -1 : R e a r c o ve r in te rlo c k s w itc h L S 5 7 -2 : F ro n t c o ve r in te rlo c k s w itc h L S 5 7 -3 : H o m e c o ve r in te rlo c k s w itc h L S 5 7 -4 : A w a y c o ve r in te rlo c k s w itc h L S 5 6 : O p e ra tio n d o o r in te rlo c k s w itc h S 1 : M a in te n a n c e k e y s w itc h
A C S e rv o D rive r KA2
KA3
5. Power supply and interlocks (for PT-R4300)
PT-R4300 SERVICE MANUAL
FU1
S in g le p h a s e A C 2 0 0 -2 4 0 V 5 0 /6 0 H z
E-69
F. Error list
F.Error list
PT-R4300 : Ver1.00
1. Error list (PT-R4300 : Ver1.00) Ex101 : Nip roller does not ascend. Ex102 : Nip roller does not descend. Ex103 : Transport unit does not ascend. Ex104 : Transport unit does not descend. Ex105 : Trail clamp arm does not ascend. Ex106 : Trail clamp arm does not descend. Ex107 : Squeeze roller does not descend. Ex108 : Squeeze roller does not ascend. Ex109 : Trail clamp cannot be locked. PH24-1/2 or M24 is illegal. Ex10a : Trail clamp cannot be unlocked. PH24-1/2 or M24 is illegal. Ex10b : Balancer drive pin cannot be initialized. Ex10c : The both of Home and Away side drive pin for the balancer can not be pulled out. Ex10d : The both of Home and Away side drive pin for the balancer can not be inserted.) Ex10e : Bar for releasing the lead clamp does not ascend. Ex10f : Bar for releasing the lead clamp does not descend. Ex110 : Shutter does not open. Ex111 : Shutter does not close. Ex112 : Plate size (in the Y direction) is shorter than the set value. Ex113 : When the plate is unloaded, the plate pass sensor (PH54-2) does not switch to ON. Ex114 : Not bring down squeeze at loading. Ex115 : Plate size (in the Y direction) is longer than the set value. Ex116 : Servo status is illegal. Ex117 : Servo status is error. Ex118 : Servo alarm. Ex11a : Drum speed is set beyond the permitted rate of the servo controller. Ex11b : Current drum's encoder pulse is beyond 4000. Ex11c : Error has occurred during drum positioning. Ex11d : When the clamp is locked, some tail clamps are detected on the clamp arm, or when the clamp is unlocked, some tail clamps are not detected on the clamp arm. Ex11e : Drum's encoder pulse is beyond the permitted range after drum positioning. Ex11f : Plate cannot be transferred into the transport unit. Ex120 : Home side balancer pin cannot be detected before insertion Ex121 : Home side balancer pin cannot be detected before pulled out (The balancer is not moving). Ex122 : Clamp arm and squeeze roller do not descend. Ex123 : Trail clamp is half-locked. Ex124 : The plate passing-sensor for unloading (PH54) does not switch to ON. Ex125 : Time-out error has occurred when the squeeze roller ascends and clamp cam PT-R4300 SERVICE MANUAL
F-1
PT-R4300 : Ver1.00
F.Error list
descends simultaneously. Ex126 : There was no plate to move to the shutter. Ex127 : Servo controller does not enter the "Ready" status. Ex128 : The balancer search sensor has not detected a balancer. Ex129 : Error has occurred on the Home side of the alignment plate (while the alignment plate is returning to its origin). Ex12a : Error has occurred on the Away side of the alignment plate (while the alignment plate is returning to its origin). Ex12b : Error has occurred on the Home and Away sides of the alignment plate (while the alignment plate is returning to its origin). Ex12c : Error has occurred on the Home side of the alignment plate (while alignment is performed). Ex12d : Error has occurred on the alignment plate (while alignment is performed). Ex12e : Error has occurred on the Home and Away sides of the alignment plate (when alignment is performed). Ex12f : Plate has not transferred to the punch unit. Ex130 : Plate does not leave the punch unit. Ex131 : Time-out error has occurred when Punch 1 is activated. Ex132 : Time-out error has occurred when Punch 2 is activated. Ex133 : Time-out error has occurred when Punch 3 is activated. Ex134 : Time-out error has occurred when Punch 4 is activated. Ex135 : Time-out error has occurred when Punch 5 is activated. Ex136 : Time-out error has occurred when Punch 6 is activated. Ex137 : Time-out error has occurred when Punch 7 is activated. Ex138 : Time-out error has occurred when Punch 8 is activated. Ex139 : After a plate is transferred to the gripper clamp, the plate detection sensor (PH29H/A) does not switch to ON. Ex13a : When the clamp arm is lowered, the sensor (to detect whether the clamp arm pins are hooked on the clamp properly) has been turned ON.(Home side) Ex13b : The specified encoder pulse for the drum is beyond 4000. Ex13c : The transport unit's Away side is not moving during its operation. Ex13d : The transport unit's Home side is not moving during its operation. Ex13e : Error has occurred on the Home side of the alignment plate (while the alignment plate is finely returning to its origin). Ex13f : Error has occurred on the Away side of the alignment plate (while the alignment plate is finely returning to its origin). Ex140 : Error has occurred on the Home and Away side of the alignment plate (while the alignment plate is returning to its origin). Ex141 : A plate remains in the transport unit when the machine received a request command. Ex142 : A plate remains in the transport unit during error handling. Ex143 : A plate remains on the discharge table in the transport unit. Ex144 : A plate remains on the insertion table in the transport unit. F-2
PT-R4300 SERVICE MANUAL
F.Error list
PT-R4300 : Ver1.00
Ex145 : Plate cannot be moved onto the discharge table during initialization. Ex146 : Plate cannot be moved onto the insertion table. Ex147 : Balancer search operation has not been completed properly. Ex148 : When the transport unit descends, only the Home side Down sensor in the transport unit is turned ON. Ex149 : When the transport unit descends, only the Away side Down sensor in the transport unit is turned ON. Ex14a : When the transport unit ascends, only the Home side UP sensor in the transport unit is turned ON. Ex14b : When the transport unit ascends, only the Away side UP sensor in the transport unit is turned ON. Ex14c : Front, rear or side cover is open.(Some interlock switches are OFF.) Ex14d : A fuse on the relay board was blown. (home) Ex14e : Thumbscrew is not tightened securely on the rear cover. (The servo stop switch is ON.) Ex14f : A plate exists on the discharge table in the transport unit during initialization. Ex150 : A plate exists on the insertion table in the transport unit during initialization. Ex151 : Number of balancers is not sufficient. (The number of balancers checked by the balancer search sensor was one, two or three for both the Home and Away sides.) Ex152 : Clamp arm is not in the UP position. Ex153 : A fuse on the relay board was blown. (away) Ex154 : Blower is turned off, but signal does not change. Ex155 : Tail clamps are missing during initialization. Ex156 : The size check program of the cetering function detects that the measured plate size is longer than the expected one. Ex157 : The size check program of the cetering function detects that the measured plate size is shorter than the expected one. Ex158 : Both of Home and Away size check sensors are on before starting the centering program. Ex159 : Auto-loader is stopped by a interlock OFF. Ex15a : This hardware matching is illegal. Ex15b : The balancer is not moved to the target position. Ex15c : The drum can not be spun up because the Home-Upper sensor of the Lead clamp release bar is off. Ex15d : During plate loading, double plate loading is detected. Ex15e : The loaded plate is detected to be floating while drum spinning. Ex15f : The drum cannot be spun up because the Upper sensor of the clamp arm is off. Ex160 : The drum can not be spined up because the Home-Upper sensor of the clamp arm is off. Ex161 : The drum cannot be spun up because the balancing pin on the (Away side) is not in the waiting position. Ex162 : The drum cannot be spun up because the balancing pin on the (Home side) is PT-R4300 SERVICE MANUAL
F-3
PT-R4300 : Ver1.00
F.Error list
not in the waiting position. Ex163 : The drum cannot be spun up because the Upper sensor of the squeeze roller is off. Ex164 : The drum can not be spun up because the Away-Upper sensor of the Lead clamp release bar is off. Ex165 : The drum is rotated to the "lead clamp position", but the status of the Servo controller (SVC) has not changed to "Ready". Ex166 : The drum is rotated to the "tail clamp position", but the status of the Servo controller (SVC) has not changed to "Ready". Ex167 : The drum is rotated to the "squeeze position", but the status of the Servo controller (SVC) has not changed to "Ready". Ex168 : The drum is rotated to the "balance pin before inserted", but the status of the Servo controller (SVC) has not changed to "Ready". Ex169 : The drum is rotated to the "balance pin after inserted", but the status of the Servo controller (SVC) has not changed to "Ready". Ex16a : The drum is rotated to the "pick up tail clamp position", but the status of Servo controller (SVC) has not changed to "Ready". Ex16b : The drum is rotated to the "plate removal position", but the status of the Servo controller (SVC) has not changed to "Ready". Ex16c : SVC Error has occurred during drum positioning for the lead clamp. Ex16d : SVC Error has occurred during drum positioning for the tail clamp. Ex16e : SVC Error has occurred during drum positioning for the squeeze. Ex16f : SVC Error has occurred during drum positioning for the balance pin insertion. Ex170 : SVC Error has occurred during drum positioning for the balance pin pull out. Ex171 : SVC Error has occurred during drum positioning for the picking up tail clamp. Ex172 : SVC Error has occurred during drum positioning for the plate removal. Ex173 : Time-out error has occurred during drum positioning.(Lead clamp position) Ex174 : Time-out error has occurred during drum positioning.(Tail clamp position) Ex175 : Time-out error has occurred during drum positioning.(Squeeze position) Ex176 : Time-out error has occurred during drum positioning.(Balance pin before inserted) Ex177 : Time-out error has occurred during drum positioning.(Balance pin after inserted) Ex178 : Time-out error has occurred during drum positioning.(Pick up tail clamp) Ex179 : Time-out error has occurred during drum positioning.(Plate removal) Ex17a : After verifying the removal of the plate, press the OK button. When the OK button is pressed, initialization begins. Ex17b : PH62A-sensor is illegal. The sensor detects a plate during initialization. Ex17c : PH29H-sensor is illegal. The PH29H-sensor does not turn ON during initialization. Ex17d : PH61H-sensor is illegal. The sensor detects a plate during initialization. Ex17e : PH61A-sensor is illegal. The sensor detects a plate during initialization. Ex17f : PH29A-sensor is illegal. The PH29A-sensor does not turn ON during F-4
PT-R4300 SERVICE MANUAL
F.Error list
PT-R4300 : Ver1.00
initialization. Ex180 : Drum does not start rotating at high-speed. Ex181 : Drum does not rotate at the specified high-speed. Ex182 : Error has occurred after the drum rotated at the specified high-speed. Ex183 : Drum cannot be stopped when rotating at high-speed. Ex184 : Drum operation is stopped with an emergency stop command. Ex185 : Drum operation is stopped with an abort command. Ex186 : Drum's vacuum pressure is not sufficient. Please confirm connection of the blower-hose, or the Vacuum-sensor is illegal. Ex187 : Error has occurred on the blower, or the power supply of the blower is OFF. Ex188 : Drum operation is stopped due to low pressure in the drum. Ex189 : Door is open. Ex18a : Door does not open. Ex18b : Transport tasks: Parameter error Ex18c : Error has occured on the blower. Please turn off this machine, and turn on after waiting 10 seconds. Also, confirm whether or not the connector doesn't come off. Ex18d : The drum can not be spun up, because some of the interlock switches are OFF, or some of the actuator's sensors are damaged, or the blower is damaged. Ex18e : Door does not open, because some of the interlock switches are OFF(front cover or rear cover is open). Ex190 : Clamp arm does not descend.(Home side) Ex191 : Clamp arm does not descend.(Away side) Ex192 : Clamp arm does not ascend.(Home side) Ex193 : Clamp arm does not ascend.(Away side) Ex194 : When the clamp arm is lowered, the sensor (to detect whether the clamp arm pins are hooked on the clamp properly) has been turned ON.(Away side) Ex195 : Trail clamp cannot be locked.(Home side) Ex196 : Trail clamp cannot be locked.(Away side) Ex197 : Trail clamp cannot be unocked.(Home side) Ex198 : Trail clamp cannot be unocked.(Away side) Ex199 : Balancer drive pin cannot be inserted.(Home side) Either of PH11-1H,PH11-2H or M11H is illegal. Ex19a : Balancer drive pin cannot be inserted.(Away side) Either of PH11-1A,PH11-2A or M11A is illegal. Ex19b : Balancer drive pin cannot be pulled out.(Home side) Either of PH11-1H,PH11-2H or M11H is illegal. Ex19c : Balancer drive pin cannot be pulled out.(Away side) Either of PH11-1A,PH11-2A or M11A is illegal. Ex19d : Balancer pin cannot be detected before insertion.(Away side) Ex19e : Balancer pin cannot be detected before pull out (the balancer is not moving).(Away side) Ex19f : The balancer search sensor has not detected a balancer.(Home side) PT-R4300 SERVICE MANUAL
F-5
PT-R4300 : Ver1.00
F.Error list
Ex1a0 : The balancer search sensor has not detected a balancer.(Away side) Ex1a1 : Number of balancers is not sufficient. (Home side) Ex1a2 : Number of balancers is not sufficient. (Away side) Ex1a3 : Soft-interlock or drum-stop swtich is OFF during drum spining. Ex1a4 : The cover-interlock switch is OFF during drum spining. Ex1a5 : The interlock switch-3 is OFF during drum spining. Ex1a6 : A plate cannot be carried into the transport unit. Ex1a7 : A plate cannot be carried to sensor PPH50-2. Ex1a8 : Auto-loader is not turned on, or some interlock switches on Auto-loader are OFF. Please turn on Auto-loader, or all interlock switch. Ex1a9 : Cassete carrier was removed. Please set cassette carrier. Ex1aa : The door of the cassette part is open. Ex1ab : Maintenance-cover of Auto-loader was opend. Please clode maintenance-cover. Ex1ac : Bridge cover-2 was opened. Please clode bridge cover-2. Ex1ad : An interleaf under a plate was detected. Or a plate size (in the Y direction) is shorter than the set value. Ex1ae : An interleaf was detected on a plate. Or a plate size (in the Y direction) is shorter than the set value. Ex1b0 : Trail clamp is not detected on the clamp arm before the plate loading. Ex1b1 : Trail clamp is detected on the clamp arm before the plate unloading. Ex1b2 : Trail clamp cannot be set correctly. Ex1b3 : This plate can't be transed. Because something error has occured when the transfering to AT. Ex1b4 : This plate can't be transed. Because trans path position is down. Ex1b6 : The bridge-passing sensor does not turn OFF.(for Jig mode) Ex1b7 : A plate remains on the plate detection sensor(PH70). Ex1b8 : When detects the front of a plate, the detection area is not brought. Ex1b9 : When detects the front of a plate, the detection of Home or Away is not brought. Ex1ba : PH11-2H-sensor is illegal. The PH11-2H-sensor does not turn ON during initialization. Ex1bb : PH11-2A-sensor is illegal. The PH11-2A-sensor does not turn ON during initialization. Ex1c0 : Lead clamp release bar cannot be driven. Either PH30H or PH31H is illegal. Ex1c1 : Lead clamp release bar cannot be driven. Either PH30A or PH31A is illegal. Ex1c2 : Trans path cannot be driven. Either PH55, PH56, or PH57 is illegal. Ex1c3 : Trans path cannot be driven. Either PH56, or, PH57 is illegal. Ex1c4 : Trans path cannot be driven. Either PH55, or, PH56 is illegal. Ex1c5 : Trans path cannot be driven. Either PH55, or, PH57 is illegal. Ex1c6 : Trail clamp arm cannot be driven. Either PH20 or PH21 is illegal. Ex1c7 : Trail clamp arm cannot be driven. Either PH20 or M20 is illegal. Ex1c8 : An interleaf was detected under a plate. Ex1c9 : When centering alignment is performed, the plate set position is out of range. F-6
PT-R4300 SERVICE MANUAL
F.Error list
PT-R4300 : Ver1.00
Ex1ca : Error has occured on the punching unit. The punch hole could not be opened correctly. Ex1cb : Opened shutter obstructs trans path driving. Ex1cc : Trail clamp arm obstructs trans path driving. Ex1cd : A plate remains in a maichine. Ex1cd : A plate remains in a maichine. Ex1d0 : Transfer operation is halted with an abort command. Ex1d1 : Transport tasks are being processed. Ex1d2 : Transport tasks are not being processed. Ex1d3 : Transport tasks: Message order error Ex1d4 : Transport system is not initialized. Ex1e0 : SVC user parameter breakdown Ex1e1 : SVC user parameter setting error Ex1e2 : SVC over-current Ex1e3 : SVC detection of regenerative error Ex1e4 : SVC postion error pulse overflow Ex1e5 : SVC Main circuit voltage error detection Ex1e6 : SVC overspeed Ex1e7 : SVC overloaded (high load) Ex1e8 : SVC overloaded (low load) Ex1e9 : SVC stauts 99h Ex1ea : SVC heat sink has overheated. Ex1eb : SVC stauts b1h Ex1ec : SVC is out of control. Ex1ed : SVC phase error has been detected in the encoder. Ex1ef : SVC A and B phase for the encoder has broke down. Ex1f0 : SVC C phase for the encoder has broke down. Ex1f1 : SVC some phases of power line is open. Ex1f3 : SVC An instantaneous loss of power has occurred Ex1f4 : SVC unknown error Ex200 : Exposure operation is interrupted with an abort command. Ex201 : Exposure processing task is now processing another command. Ex202 : Cancellation was requested while processing was not being performed. Ex203 : PGON is not asserted. Ex204 : START signal is not asserted. Ex205 : START signal is not negated. Ex206 : Test pattern; Data is not transferred. Ex207 : Test pattern; Data transfer is not completed. Ex208 : Reset procedure for RB31 board is not completed. Ex209 : The set value for the drum rotation speed is too large. Ex20a : No plate edge is detected (when the plate edge sensor moves to the Away side.) Ex20b : No plate edge is detected (when the plate edge sensor is returning to the Home PT-R4300 SERVICE MANUAL
F-7
PT-R4300 : Ver1.00
F.Error list
side.) Ex20c : Recording head has traveled beyond the limit (on the Away side). Ex20d : Recording head has traveled beyond the limit (on the Home side). Ex20e : Recording head positioning range error Ex20f : Recording head has not been positioned at its origin. (Origin sensor does not turn OFF.) Ex210 : Recording head has not been positioned at its origin. (Origin sensor does not turn ON.) Ex211 : Emergency stop is requested for the secondary-scanning motor. Ex212 : Secondary-scanning motor is deactivated with an abort command. Ex213 : Secondary scanning motor is illegal. Ex214 : Exposure in the secondary scanning direction exceeds the effective image output range. Ex215 : FPGA sequence error. Ex216 : Time-out error has occurred when the secondary scanning motor is activated. Ex217 : EZ search has not detected the ORG sensor. Ex218 : EZ search has not detected the EZ sensor. Ex219 : When the CAL sensor search was executed, the maximum light intensity was less than 50 mW. Ex21a : Light intensity at the measurement starting point was at maximum when the CAL sensor search was executed. Ex21b : Light intensity at the measurement end point was at maximum when the CAL sensor search was executed. Ex21c : Over travel at recording head's Home side when the CAL sensor search was executed. Ex21d : Test pattern parameter error Ex21e : PGON signal is not negated. Ex21f : Secorndary direction origin point setup procedure failure.(The calibrated origin point is not the same as logical origin point) Ex220 : After an image data transfer from RIP is interrupted, it isn't resumed. Ex221 : Drum rotation error was detected. This plate will be unloaded because it could not be exposed correctly. Ex300 : Both of plate pad and paper pad are not in original point. Ex301 : After an interleaf is removed, plate cannot be detected. Ex302 : An interleaf was detected on a plate. Or a plate size (in the Y direction) is shorter than the set value. Ex303 : Plate pad cannot be initialized. Ex304 : Plate pad cannot carry a plate. Ex305 : While carring a plate, the plate pad dropped the plate. Ex306 : Paper pad cannot be initialized. Ex307 : Air pressure in the plate pad does not go down. Ex308 : Air pressure in the paper pad does not go down. Ex309 : PCL time-out error has occurred when plate pad was moved. F-8
PT-R4300 SERVICE MANUAL
F.Error list
PT-R4300 : Ver1.00
Ex30a : PCL time-out error has occurred when paper pad was moved. Ex30b : Time-out error has occurred when plate pad was moved by stepping. Ex30c : Time-out error has occurred when paper pad was moved by stepping. Ex30d : A plate cannot be carried into the transport unit. Ex30e : PH90 does not switch to ON while removing the interleaf. Ex30f : PH90 does not switch to OFF while removing the interleaf. Ex310 : Maintenance cover of auto-loader is open. Please close maintenance cover. Ex311 : Bridge cover-2 of auto-loader is open. Please close bridge cover-2. Ex312 : Cassette carrier is not set. Please set cassette carrier. Ex313 : A plate remains in the bridge unit. Ex314 : An interleaf remains in the paper exit. Ex315 : Nip roller does not ascend. Ex316 : Nip roller does not descend. Ex317 : Auto-loader is not turned on, or some interlock switches on Auto-loader are OFF. Please turn on Auto-loader, or all interlock switch. Ex318 : A plate cannot be carried to the bridge-passing sensor. Ex319 : The plate pad went down from the original point. Ex31a : The paper pad went down from the original point. Ex31b : Maintenance-cover of Auto-loader was opend. Please clode maintenance-cover. Ex31c : Bridge cover-2 was opened. Please clode bridge cover-2. Ex31d : Door was opened. Please close the door. Ex31e : Cassete carrier was removed. Please set cassette carrier. Ex31f : The paper pad dropped the interleaf while carrying the it. Ex320 : Plate pad dropped a plate before the plate pad reached the intermediate sensor. Ex321 : An interleaf in front of a plate was detected. Ex322 : A plate remains on the sensor-2 of the bridge. Ex323 : Intermediate sensor is OFF. Ex324 : Power switch was turned off while Auto-loader was moving. Ex325 : A plate cannot be carried to the intermediate sensor. Ex326 : An interleaf under a plate was detected. Or a plate size (in the Y direction) is shorter than the set value. Ex327 : The bridge-passing sensor does not turn OFF.(for Jig mode) Ex328 : Door is open. Ex32c : The nip-roller for paper discharge cann't be opened. Ex340 : Door is open. Ex341 : The interlock switch-3 is OFF. Ex342 : The interlock switch-2 is OFF. Ex343 : The interlock switch-1 is OFF. Ex344 : A fuse on the relay board at home side has blown. Ex345 : A fuse on the relay board at away side has blown. Ex346 : Nip roller does not descend. PT-R4300 SERVICE MANUAL
F-9
PT-R4300 : Ver1.00
F.Error list
Ex347 : Nip roller does not ascend. Ex348 : Shutter does not open. Ex349 : Shutter does not close. Ex360 : A plate remains on the bridge's sensor-1. Ex361 : No plate exists on the bridge's sensor-3. Ex362 : A plate remains on the bridge's sensor-3. Ex363 : A plate size in the Y direction is too long when its transferring to the AT. Ex364 : A plate size in the Y direction is too short when its transferring to the AT. Or an interleaf in front of a plate was detected. Ex365 : After the paper pad is descended, the metal sensor does not switch to ON. Ex366 : Plate pad dropped the plate, before this initialize. Ex367 : A teaching of plate size in the Y direction (1st) is finished. Ex368 : A teaching of plate size in the Y direction (2nd) is finished. Ex369 : This plate can't be transed. Because something error has occured when the transfering to AT. Ex36a : Air pressure in the plate pad does not go down after retry. Ex36b : A plate remains on the insertion table in the transport unit. Ex36c : This plate is judge as a paper during judgement operation. Ex36d : This plate can't be transed. Because trans path position is down. Ex380 : The door of the cassette part is open. Ex381 : Time-out error has occurred when lift was initialized. Ex382 : Time-out error has occurred when lift was moved. Ex383 : Though the lift was initialized, the origin sensor is not ON. Ex384 : The lift is not in the position where it is specified. Ex385 : Already, there has been a cassette on the lift. Ex386 : There are some cassettes which aren't being set properly. Ex387 : MA-L can't be initialized because some cassettes are not in the lift or the cassette properly. Ex388 : There is no cassette in the specified cassette slot. Ex389 : There is no cassette on the lift. Ex38a : Lift has traveled beyond the limit (on the Up side). Ex38b : Lift has traveled beyond the limit (on the Down side). Ex38d : A cassette is already in the place to return a cassette. Ex38e : A lift can't be raised and lowered because some cassettes are not in the lift or the cassette properly. Ex38f : Time-out error has occurred when a cassette was moved to cassette part. Ex390 : Time-out error has occurred when a cassette was moved to lift. Ex391 : Either plate pad or paper pad is not in original point. Ex392 : An ineffective cassette number was indicated. Ex393 : Cassette has traveled beyond the limit (on the Lift side). Ex394 : Cassette has traveled beyond the limit (on the Cassette side). Ex395 : MA-L can't be initialized because some cassettes can't be returned to the origin. Ex396 : Though there is a cassette on the lift, the place to return the cassette isn't F-10
PT-R4300 SERVICE MANUAL
F.Error list
PT-R4300 : Ver1.00
vacant. Ex397 : Though the movement of the lift was finished, the lift position sensor at the target position is not on. Ex398 : MA-L Servo alarm Ex399 : Time-out error has occurred when arm was moved. Ex39a : Time-out error has occurred when a cassette was moved to cassette part by arm. Ex39b : Arm jut-out sensor (LS210E) is off. Ex39c : A cassette is in illegal position of the cassette slot. Ex39d : Arm is not in original point. Ex39e : SQ210A sensor is illegal. Ex400 : Plate has already been loaded. Ex401 : Plate has not been loaded. Ex402 : Door is open. Ex403 : Dump interleaves from the collection box. Ex600 : Either the conveyor, processor, or stocker is not turned on, or is in the busy status or error status. Ex601 : Either the conveyor, processor, or stocker is not turned on, or is in the busy status or error status. Ex602 : The plate cannot be transferred into the AT unit. Ex603 : The plate cannot be transferred completely into the AT unit. Ex606 : Error Ex607 : Busy Ex608 : Error Ex609 : Busy Ex60a : Error Ex60b : Busy Ex60c : Error occurred in ATM while a plate was carried to ATM. Ex80c : The result of the calculation "Initial value + increment value * (repetition - 1)" exceeds the upper limit value. Ex80d : (The result of the calculation "Exposure starting point + (pattern width + gap) * (repetition - 1)" exceeds the plate size. Ex80e : The specified plate is not linked with the printing-machine's data. Ex80f : Perform initialization at the service screen. Ex810 : No plate is set at inlet of transport unit. Ex811 : Plate (printer) size specified by the host computer is not registered. Ex812 : Image size specified by host computer is larger than allowable output image size. Ex813 : Current offset of printing machine settings cause image to extend off plate. Ex814 : Current paper-position of printing machine settings cause image to extend outside of allowable exposure area. Ex816 : Some LD is nearing the end of its usable life. Please contact our office or agency and ask to replace them. PT-R4300 SERVICE MANUAL
F-11
PT-R4300 : Ver1.00
F.Error list
Ex817 : There are some punch blocks, which have been used for more than the endurance time. Please contact our office or agency and ask to replace them. Ex819 : It failed to read the cassette number. It considers that the cassette number is No.1. Ex81a : Some LD's cannot be calibrated to the target power. These LD's be calibrated to lower target power. Please contact our office or agency and ask to replace them. Ex81b : Some LD's cannot be calibrated to the target power. Temporary to work half channels of recording head. Please contact our office or agency and ask to replace them. Ex81c : Some LD's cannot exposed by setting power due to be calibrated to lower target power. Please contact our office or agency and ask to replace them. Ex81d : The temperature of the environment is greater than 28degrees. Ex81e : The temperature of the environment is less than 18degrees. Ex81f : Sensor for the temperature of the environment has not been connected. Ex820 : Trail clamps are nearing the end of its usable life. Please contact our office or agency and ask to replace them. Ex821 : Trail clamps have been used for more than the endurance time. Please contact our office or agency and ask to replace them. Ex822 : Backup/restore of the data on NVRAM can't be performed, because the Dip-Sw 2 is not on. Ex823 : The backup of the data on NVRAM is not in Flash-Memory. Ex824 : Calibration must be done because there is some LD which doesn't reach the target power. But, LD calibration can not processed because temperature of LD block is too low. Ex825 : The direction where a connected conveyer can't be changed is set up in the plate types setting. Ex826 : No respons was returned from the conveyer. Ex827 : An error was returned from the conveyer toward the switching command. Ex828 : The conveyer can't be changed to the direction that is set up in the plate types setting. Ex82a : Since the light intensity of laser diodes is detected as having deviated more than +-5% from the specified value, the equipment executes the calibration. Ex82b : Communication with the RAS server was interrupted. (RAS server was turned off, or RS-232C cable was drawn out) Ex82c : No response come from DNS. Ex82d : Communication with the RAS server has resume. Ex82e : It failed in the connection to the rotating light server. Ex82f : The name of the mail server isn't right. Ex830 : It failed in the connection to the mail server. F-12
PT-R4300 SERVICE MANUAL
F.Error list
PT-R4300 : Ver1.00
Ex831 : Mail account was rejected. Ex832 : An error occurred in the transmission of DATA command. Ex833 : An error occurred in the transmission of header. Ex834 : An error occurred in the transmission of body. Ex835 : An error occurred in the transmission of attached file. Ex836 : An error occurred in the transmission of TO command. Ex837 : A command was sent to the SMTP server. But, no answer was returned from the server. Ex839 : The cable between RB31 board and recording head is disconnected. Please contact our office or agency and ask to replace them. Ex880 : Servo pack: Time-out error occurred while receiving data. Ex881 : Servo-Pack:Address error Ex882 : Servo-Pack:Data error Ex883 : Servo-Pack:Check sum error Ex884 : Servo-Pack:Undefined error code Ex885 : Servo-Pack:Number of received characters are insufficient. Exe01 : Excessive current in the LD drive (driver 1 board) Exe02 : Excessive current in the LD drive (driver 2 board) Exe03 : Excessive current in the LD drive (driver 3 board) Exe04 : Excessive current in the LD drive (driver 4 board) Exe05 : Driver board temperature error or Head FPGA Version Error Exe06 : -5 V power supply error Exe07 : Calibration sensor is not connected. Exe08 : Offset error in the calibration sensor Exe09 : Irregular 5 V power supply Exe0a : Irregular +15 V power supply Exe0b : Irregular -15 V power supply Exe0c : Irregular 24 V power supply Exe0d : Cover switch is OFF. Exe0e : BL command error (counter value is 0) Exe0f : Zoom sensor is not detecting. Exe10 : Focus sensor is not detecting. Exe11 : Time has expired for home return.(Zoom or focus motor) Exe12 : Power supply irregular while the motor is driving Exe13 : Pulse motor has traveled beyond the limit. (Zoom or focus motor) Exe14 : Irregular power supply(instantaneous loss) Exe20 : Temperature of the LD block is greater than 28degrees. Exe21 : Temperature at the periphery of the optical unit is greater than 35degrees. Exe22 : Temperature of the radiating fin of the Peltier element is greater than 55 degrees. Exe23 : Dew condensation error Exe24 : Sensor for LD block has not been connected. Exe25 : Sensor for the periphery of the optical unit has not been connected. PT-R4300 SERVICE MANUAL
F-13
PT-R4300 : Ver1.00
F.Error list
Exe26 : Sensor for the radiating fin of the Peltier element has not been connected. Exe27 : The dew condensation detection sensor has not been connected. Exe28 : Temperature of the LD block is low. Exe30 : Power supply error occurred when the recording head received the DW command. Exe31 : Command error occurred when the recording head received the DW command. Exe32 : Download error occurred when the recording head received the DP command. Exe33 : Download error occurred when the recording head received the DF command. Exe34 : Download address error occurred. Exe35 : Error occurred when the recording head received the BU command. Exe36 : Error occurred when the recording head received the BD command. Exe40 : Writing error occurred when the recording head received the AC command. Exe41 : Writing error on EEPROM Exe42 : RAM error Exe43 : ROM check sum error Exe44 : FPGA error Exe45 : Data error due to a divide-by-zero error Exe60 : LD Current setting Error Exe61 : The temperature of the LD block is greater than 28degrees. (Temperature at the periphery of the optical unit > 35degrees. Temperature of the environment = 18degrees.) Exe6b : The temperature of the LD block is greater than 28degrees. PT-R4300 SERVICE MANUAL
F-31
PT-R4000 : Ver3.0X
F.Error list
PT-R4000II : Ver4.0X
(Temperature at the periphery of the optical unit > 35degrees. Temperature of the environment 28degrees.) Exee3 : The temperature of the radiating fin is greater than 55degrees. (Temperature at the periphery of the optical unit > 35degrees. Temperature of the environment > 28degrees.) Exee4 : It is just before a recording head has dew. (Temperature of the LD block >= 22degrees.) Exee5 : The temperature of the LD block is less than 5degrees. (Temperature at the periphery of the optical unit < 17degrees. Temperature of the environment < 18degrees.) Exef0 : Recording head processing task is now processing another message. Exef2 : Recording head unit is not running. Exef3 : Recording head data check sum error occurred when data was uploaded. Exef4 : Recording head data address error occurred when data was uploaded. Exef5 : LD calibration cannot process because temperature of LD block is too low. Exef6 : A command was sent to the exposure head. But, no answer was returned from the exposure head. Exfa0 : System error(stack overflow). Exfa1 : Floating point arithmetic error Exfa2 : Divide-by-zero error Exfa3 : System error (semaphore) Exfb0 : Flash memory erase error Exfb1 : Flash memory erase error (during verification). Exfb2 : Flash memory write error. Exfb3 : Incompatible flash memory PT-R4300 SERVICE MANUAL
F-33
G. Supplement
G.Supplement
1. Punch List
Parts cord U1250039-00 U1250040-00 U1250041-00 U1250042-01 U1250043-01 U1250044-01 U1250045-01 U1250046-01 U1250047-01 U1250048-00 U1250049-01 U1250050-01 U1250051-01 U1250052-01 U1250057-00 U1250108-00 U1250060-01 U1250061-01 U1250058-00 U1250063-01 U1250069-00 U1250104-00 U1250106-00 U1250107-00 U1250113-00 U1250119-00 U1250110-00 U1250121-00 U1250118-00 U1250120-00 U1250059-00 U1250111-00 U1250115-00
Parts Name HB-S220 HB-S425 HB-S220/425 DS400 DS500 DS700 DS400/700 DS400/700 DS500/700 KM550 HB-W425 PC458 PC757 PC458/757 HB-S425(UU) HB-S220(UU) DS400/KM550(8/9) DS400/KM550(7/9) HB-S425+KM550 HB(W)425/393+KM550 HB/DS(W)425/400(11/8) HB/DS(W)425/400(11/6.25) HB(W)425/393+DS550 HB/DS(W)425/400(11/10) HB(W)425/393+DS700 HB/DS(W)425/400(11/6) PC737/KM550 PC458/KM550 HB/PC(W)425/457(11/11) HB/PC(W)425/457(11/10) HB/DS(W)425/400+KM550(10/9) HB/DS(W)425/400+KM550(11/9) DS/KM(W)500/550+HB425(10/11,8)
* U1250039-00 to U1250052-01 is Standard option
PT-R4300 SERVICE MANUAL
G-1
G.Supplement
G-2
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G.Supplement
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G-3
G.Supplement
G-4
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G.Supplement
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G-5
G.Supplement
G-6
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G.Supplement
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G-7
G.Supplement
G-8
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G-9
G.Supplement
G-10
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G.Supplement
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G-11
G.Supplement
2. Recommend parts list
2002-05-23 present G-12
PT-R4300 SERVICE MANUAL
G.Supplement
2002-05-23 present PT-R4300 SERVICE MANUAL
G-13
G.Supplement
2002-05-23 present G-14
PT-R4300 SERVICE MANUAL
G.Supplement
2002-05-23 present
PT-R4300 SERVICE MANUAL
G-15
Plate Thermal Recorder
4300
SERVICE MANUAL June,6,2002 Ver1.1 Publication Quality Promotion Department Media Technology Company DAINIPPON SCREEN MFG.CO.,LTD. Printed in Japan