SERVICE MANUAL VICE MANUAL

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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

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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

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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

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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

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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

C-31

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.

C-48

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.

C-52

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.

PT-R4300 SERVICE MANUAL

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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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PT-R4300 SERVICE MANUAL

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.

PT-R4300 SERVICE MANUAL

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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.

PT-R4300 SERVICE MANUAL

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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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PT-R4300 SERVICE MANUAL

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.

PT-R4300 SERVICE MANUAL

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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 )

PT-R4300 SERVICE MANUAL

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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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PT-R4300 SERVICE MANUAL

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.

PT-R4300 SERVICE MANUAL

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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

PT-R4300 SERVICE MANUAL

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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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C.Replacement & Adjustment

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

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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

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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

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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

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2. Recommend parts list

2002-05-23 present G-12

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2002-05-23 present

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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