Magnum

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PURUP IMAGEMAKER MAGNUM
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PURUP IMAGEMAKER MAGNUM
SERVICE MANUAL
Rev. G June 1998
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PURUP IMAGEMAKER MAGNUM REVISION STATUS
REV. G
Purup ImageMaker MAGNUM Service Manual Revision Status This manual is revision G. The revision status of the pages is: Revision B: All pages except for those mentioned below: Revision C: Main Table of Contents Pg. 4.1.1-4.1.2, chp. 4.4, chp. 4.5 Chapter 4: Chp. 10.2 Chapter 10: Revision D: Chapter 2: Chapter 3: Revision E: Chapter 1: Chapter 2: Chapter 3: Chapter 9: Revision F: Chapter 1: Chapter 2: Chapter 3: Chapter 7: Revision G: Chapter 6:
Chp. 2, except for those mentioned below Chp. 3, except for those mentioned below
Chp. 1.4, 1.5 (except rev. F) Pg. 2.1.3-4, pg. 2.1.3-22, chp. 2.8 Chp 3.1, pg. 3.2.3-41, pg. 3.2.15-18 Chp. 9.1
ToC1, pg. 1.4.7-1.4.8, pg. 1.5.7-1.5.20 ToC2, 2.1.23-2.1.26, chapter 2.3, pg. 2.5.3-4 ToC3, pg. 3.1.11-12, chp. 3.3 ToC 7
ToC6, chp. 6.2, chp. 6.3 Front Page, Revision Page
This page indicates the revision status of the Purup ImageMaker MAGNUM Service Manual, and it will be updated each time the manual is revised. This page must be placed right before the Main Table of Contents of the Purup
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PURUP IMAGEMAKER MAGNUM GENERAL INFORMATION
PAGE 1.1.1
1.
General Information
1.1. Limitations
WARNING!
This manual is not addressed to users of the product in question. As regards extent and level of detail, the descriptions are in a form where correct use implies special training. Therefore, this service manual must only be used by service technicians who are trained and authorized by Purup Prepress A/S. Purup Prepress A/S takes no responsibility for damage or loss that may occur directly or indirectly in connection with unauthorized use of this service manual.
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PURUP IMAGEMAKER MAGNUM SAFETY
PAGE 1.2.1
1.2. Safety
The following general safety precautions must be observed during all phases of operation, maintenance, service, and repair of this equipment. Failure to comply with these precautions or with specific warnings elsewhere in this manual violates safety standards of design, manufacture, and intended use of the equipment. Purup Prepress A/S assumes no liability for the service personnel's failure to comply with these requirements. The safety precautions listed below represent warnings of certain dangers of which we are aware. Service personnel should follow these warnings and all other safety precautions necessary for the safe operation of the equipment.
Earth the instrument
To minimize shock hazard, the chassis and enclosure must be earthed. The equipment is supplied with three-conductor AC power cables. The power cables must be plugged into an approved three-pin socket with the earth wire (green/yellow) safely connected to electric earth (safety earth) at the power outlet.
Do not operate in an explosive environment
Do not operate the equipment in the presence of flammable gases or fumes. Operation of any electrical equipment in such an environment constitutes a definite safety hazard.
Keep away from live circuits
Operating personnel must not remove equipment covers. Only factory-authorized service personnel or other qualified maintenance personnel may remove equipment covers for internal subassembly or component replacement or any internal adjustment. Do not replace components with power cable connected. Under certain conditions, dangerous voltages may be present even when the power cable has been removed. To avoid injuries, always disconnect power and discharge circuits before touching them.
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Do not service or adjust alone
Do not attempt internal service or adjustment unless another person, capable of rendering first aid and resuscitation, is present.
Use caution when exposing or handling the CRT
Breakage of the Cathode-Ray Tube (CRT) causes a high-velocity scattering of glass fragments (implosion). To prevent CRT implosion, avoid rough handling or jarring of the equipment. Handling of the CRT should be done only by qualified maintenance personnel using approved safety mask and gloves.
Do not substitute parts or modify equipment
Because of the danger of introducing additional hazards, the customer should not install replacement parts or perform any unauthorized modification of the equipment. Purup Prepress A/S' Field Service Division should be contacted for service and repair to ensure that safety features are complied with.
Dangerous Procedure warnings
Warnings, such as the example below, precede potentially dangerous procedures throughout this manual. Instructions contained in the warnings must be followed. You should also employ all other safety precautions which you deem necessary for the operation of the equipment.
Radiation of Radio Frequency Energy
Warning: This equipment generates, uses, and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual, may cause interference to radio communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such SERVICE MANUAL PURUP PREPRESS A/S
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PAGE 1.2.3
interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case the user at his own expense will be required to take whatever measures may be required to correct the interference.
Disposal
Laser tube: This tube contains beryllium oxide. Never dispose of used tubes with normal waste! Laser tube from a scrapped product or a defect tube may be returned to the manufacturer for decontamination
Warning Dangerous voltages, capable of causing death, are present in this equipment. Use extreme caution when handling, testing, and adjusting this equipment.
Laser Safety
The MAGNUM complies with the IEC825 radiation Safety of Laser Products, equipment classification, requirements and user's guide, and the US Food and Drug Administration FDA radiation performance standards, 21 CFR subchapter J.
DANGER
VISIBLE AND INVISIBLE LASER RADIATION WHEN MACHINE COVERS ARE REMOVED FOR SERVICE AVOID DIRECT EXPOSURE TO BEAM
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WARNING LASER RADIATION AVOID DIRECT EXPOSURE TO BEAM CLASS 1 Laser Product
This means that this is a class of laser product which does not emit hazardous laser radiation. It is only possible because the laser beam is totally enclosed during all modes of operation. For safe use of the MAGNUM the following procedures must be observed: 1. 2. Only trained operators may operate the system. Only authorized technicians from Purup Prepress A/S' field service organization may carry out service on the system. Do not wear highly reflective rings, bracelets, watches, etc. Never look directly into the laser beam Check that the Purup system is maintained in compliance with regulations and that all safety regulations are met. If using control buttons, adjustments, or procedures other than those described in this manual, you may expose yourself to dangerous laser radiation. Marking: The MAGNUM is fitted with warning signs where there is a potential risk of laser radiation.
3. 4. 5.
6.
7.
Warning labels are printed on a yellow background with text, signs and frame in black.
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The warning labels used are shown below: CAUTION VISIBLE AND INVISIBLE LASER RADIATION WHEN OPEN DO NOT STARE INTO BEAM
LASER RADIATION AVOID EXPOSURE TO BEAM CLASS 3B LASER PRODUCT
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PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION
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1.3. General Description
The MAGNUM is a high speed, high resolution laser imagemaker. It receives bitmap data from an external PS-Link and exposes it by means of a laser on film or plates. It functions according to the internal drum principle with a cast-iron drum and air bearing spinner. The exposure source is either an infrared laser diode or an Argon-Ion gas laser. The MAGNUM can be operated in daylight, and the machine is connected to an on-line film processor. The MAGNUM can be equipped with an internal climate control system which keeps temperature and humidity at a constant level inside the machine to ensure high accuracy. The MAGNUM has a PC connected, which is used for manual operation of the MAGNUM and monitoring the conditions inside the MAGNUM. It also gives the operator an error indication, and at the same time it updates an error log file.
1.3.1. Functional Specifications Electrical Data
1.3.1.1. Format
1.3.1.1.1. Recording Format
Max. (vertical x horizontal): Horizontal: Vertical:
820 x 1200 mm or 32.3 x 47.2 inch around drum along drum
1.3.1.1.2. Photographic Material Format
Max. (vertial x horizontal): Min. (vertical x horizontal):
820 x 1200 mm 400 x 250mm
The entire film can be exposed with exception of shadows around register punch holes.
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1.3.1.2. Tolerances
1.3.1.2.1. Absolute Linearity
Absolute linearity is expressed as the difference between measured distance between two points and nominal measure. Error values are divided into the following main groups: 1. Geometric scan errors (primarily mechanical and optical errors) = overall accuracy Temperature errors of the mechanical parts. Influence of air temperature variation on the film. Influence of air humidity variation on the film.
2. 3. 4.
Group 1 expresses constants for the machine when it has been adjusted. Group 2 to 4 variables within:

Specifications of the climate control. Film type and make. Film thickness. Film curl / non curl.
The curves on the next pages are based on: Film AGFA GEVASCAN S 712 p NEW, 0.1 mm thickness, no curl. The curve expresses linearity in both x and y direction, however, the value of the geometrical scan errors in the y direction (along the drum) will often be considerably smaller.
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Error [ m]
50
40
Total "worst case"
30
20
10

[mm] 100 200 300 400 500 600 700
20 in.: Max. format y-direction 26 in.: Max. format x-direction
The curve specifies the absolute linearity on film for the x and y axis. (5) total is the sum of error values from group (1) to (4) . (5) total expresses thus the absolute linearity "worst case" for a film loaded to the input slit of the processor or cassette. The absolute linearity for the "worst case" expresses maximal error values for all main groups. This will rarely occur. Especially the x direction will typically be considerably smaller. The influence of the processor on the linearity is not expressed in the above section. Values from the RIP truncation are not included! For better linearity the values of humidity and temperature variations can be reduced considerably by use of a 0.18 mm film base thickness.
1.3.1.2.2. Repeatability
The repeatability is defined as differences between the distances between identical grid lines measured on the same positions on two different films.
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Thus, the error from the register system is added to the zero point on the film according to the axis direction. The error values are divided into the following main groups: 1. 2. 3. 4. 5. Geometric scan errors. Temperature errors of the mechanical parts. Influence of air temperature variation on the film. Influence of air humidity variation on the film. Errors from register to zero point.
The geometric scan errors as regards the repeatability are < 1 m, which is why they are counted as 0 below. Group 2 to 4 are variables within:

The specifications of the climate control. Film type and make. Film thickness. Film curl / non curl.
Following curves are based on: Film AGFA GEVASCAN S 712 p NEW, 0.1 mm thickness, no curl.
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Error [ m]
30
Total "worst case"
20
10

[mm] 100 200 300 400 500 600 700
20 in.: Max. format y-direction 26 in.: Max. format x-direction
The curve specifies the repeatability on film for the x and y axis. Total is the sum of error values from group (2) to (5). (6) total expresses thus the repeatability "worst case" for a film loaded to the input slit of the processor or cassette. The repeatability for the "worst case" expresses maximal error values for all main groups. This will rarely occur. The error will be reduced considerably when film exposed successively are compared. The influence of the processor on the linearity is not expressed in the above section. Values from the RIP truncation are not included! Note: For better repeatability the values of humidity and temperature variations can be reduced considerably by use of a 0.18 mm film base thickness.
1.3.1.3. Resolution
20 m <<=>> 0.0008 inch 10 m <<=>> 0.0004 8 m <<=>> 0.0003 6.4 m <<=>> 0.0002 5 m <<=>> 0.0002
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1.3.1.3.1. Addressability
500 lines /cm <<=>> 1270 lines /inch 1000 lines /cm <<=>> 2540 lines / inch 1250 lines/cm <<=>> 3175 lines/inch 1563 lines/cm <<=>> 3969 lines /inch 2000 lines/cm <<=>> 5080 lines/inch
1.3.1.3.2. Recording Spot Size on Film
26 m at 20 m in addressability 13 m at 10 m in addressability 10.4 m at 8 m in addressability 8.4 m at 6.4 m in addressability 8.4 m at 5 m in addressability
1.3.1.3.3. Recording Speed (10 and 20 m) 1.3.1.4. Screen Variations
16 mm/sec (20 m) 8 mm/sec (10 m)
+/- 1% relatively measured.
1.3.1.5. Density Variations
Maximum standard variation of selected density:
+/- 0.15
1.3.1.6. Register System
Head, tail and side punch selected from 20 standard systems. Possibility of customer specified register.
1.3.1.6.1. Register System Limitations
Maximum number of punch units (standard):
14
Minimum distance from the first possible exposure zero point to the centre of first hole 17 mm Maximum distance from the exposure zero point to the centre of the last hole Minimum distance between punch holes
1180 mm 38 mm
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Maximum size of the punched holes Minimum size of the punched holes Note:
9.52 mm 3.00 mm
Tailor-made systems may vary from these specs!
1.3.1.6.2. Register System Tolerances
Repeatability of the image position with reference to the punched holes Maximum displacement of punched holes from the mutual centre line of the punches Maximum angular displacement of the punches' mutual centre line in relation to the X-direction of exposure Maximum variation in the nominal hole size Maximum variation in the distance between the holes Maximum consumption of film for punching holes
+ 0.01 mm
max. 0.02 mm
0.1 mm/600 mm
+0/-0.005 mm
+ 0.30 mm
Shadows around the punch units 50/20 mm
Normal distance from the film edge to the centre line Corresponding Pin Bar
8 +2 mm
Film punched in the MAGNUM will fit register pins and bars manufactured according to the following tolerances: - tolerances for reference pins - tolerances for secondary pins X direction - tolerances for secondary pins Y direction - tolerances for the displacement of pins from the mutual centre line -0/+0.02 mm -1.0 mm -0/+0.02 mm +0.02 mm
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1.3.1.7. Photographic Material
Infrared 780 nm, red 650 nm or blue 488 nm sensitive material on polyester base (films and polyester plates): Thickness (TH): 0.10 mm to 0.20 mm
1.3.1.8. Light Source
Infrared laser diode 780 nm, red laser diode 650 nm or argon-ion laser 488 nm
1.3.1.9. Photographic Material Transport
1. 2. 3. 4. 5.
6. 7. 8.
Automatic film load Roll to sheet Magazine with 3 rolls On-line to processor or to cassette (cassette is not supplied by Purup Prepress). Transport time for sequence: film in, cut, film out: max. 80 sec. Mean Time Between Jam (MTBJ): 1 out of 1,000 sheets. Parallel displacement out of machine: +/- 5 mm Film consumption at film roll change: 250 mm
1.3.1.10. Photographic Material Specification
1. 2. 3. 4. 5. 6. 7. 8.
Max. width: Min. width: Max. diameter: Film thickness: Curl: Emulsion: Storage:
Humidity: Temperature: Daylight loading
820mm 400mm 130 mm 0.10 mm to 0.20 mm 0 to + 6 ANSI / ASC PH 1.29 - 85 inside of roll 50% +/- 5% RH at 20oC 21oC, or below
1.3.1.11. Temperature and Humidity Control
Around the drum and film roll magazine there is a climatic zone in which temperature and humidity can be controlled with the following accuracy, if the ImageMaker has an optional climate control unit.
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Temperature: Humidity:
22oC +/- 2oC 44%RH
The temperature and humidity control system must be switched on 24 hours a day when loaded with film.
1.3.1.11.1. Influence of Variations in Air Temperature on Dimensional Stability of Film
Film temperature is determined by the ambient temperature, especially that of the film magazine and the drum. Variations in air temperature are decreased by the magazine aluminium and the cylinder cast iron. The variation of the film during exposure is thus half the variation of the air. air t = film t = 4oC 2oC
The expansion for AGFA's GEVASCAN S 712 p NEW 0.1 m thickness is 18 /m per degree Celsius Maximum errors on the film due to air temperature variations 36 m/m
1.3.1.11.2. Influence of Variations in Air Humidity on Dimensional Stability of Film
The following calculations are made on the specifications of AGFA's GEVASCAN S 712 p NEW 0.1 mm base thickness. * Adaptability in minutes necessary for obtaining balance after changes in RH PCT Balance 40% 5 min. 60% 15 min. 80% 60 min. 100% 300 min.
* According to AGFA: Dimensional stability of reprographic film The expansion for AGFA's GEVASCAN S 712 p NEW 0.1 mm thickness is 13 /m per % RH
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Measurement variations due to humidity variations are limited to max. 40 m/m at any time. The demand to the humidity regulation is thus:
Time period 300 min 60 min 15 min 5 min
Average allowed % RH Variations 3.0% 3.8% 5.1% 7.5%
Error on film
40m/m 40m/m 40m/m 40m/m
The temperature and humidity control system must always be switched on when loaded with film.
1.3.1.11.3. Influence of Variations in Air Temperature on Mechanical Parts
Steel/cast iron expands by 12 m/m per degree Celcius! The main values will be the spindle heating by rapid traverse of the carriage, air cooling/heating of the drum, and the spinner/spinner motor heating of the suspension/carriage system. For the x and y direction these factors contribute with 20 m per meter
1.3.1.12. Geometrical Scan Errors
The following components contribute to geometrical scan errors:

Spinner eccentricity in relation to drum Drum roundness Laser beam alignment Encoder disk graduation eccentricity Spindle pitch error
The value for drum roundness is close to zero, and the encoder eccentricity contributes with very small values. Therefore, they are both counted as 0.
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1.3.1.12.1. Spinner Eccentricity
As the maximum allowed spinner eccentricity is +/- 5 m, maximum error on the film is: 20 m per 800 mm This error is in the x direction (around in the drum)
1.3.1.12.2. Laser Beam Alignment
The beam alignment is adjusted to 10 m for angular errors 20 m for parallelity errors In focus only angular errors are depicted by 1:1, and errors due to laser beam alignment are thus: 20 m per 800 mm This error is in the x direction (around the drum)
1.3.1.12.3. Spindle Pitch Errors
The spindle is classified G5 quality which is maximum: 27 m per 500 mm This error is in the y direction (along the drum)
1.3.1.13. Acoustic Noise
Maximum:
45 dBA
1.3.1.14. Personal Computer
MAGNUM is controlled by a PC. Type: Siemens Nixdorf Scenic 4L
1.3.1.15. Bitbus Interface
Speed: Isolation: Board type:
375 kbaud optically isolated DICE PC Master/Node Processor Board = P/N 52749-400 with on board 16 kByte RAM (In general called BBM).
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1.3.1.16. Data Transmission 1.3.1.16.1. Data Interface Interface to RIP is implemented with an asynchronous optical fibre link with TAXI chi, based on the FDDI system. Encoding: ANSI X3T9.5 Transmission speed: 80 Mbit/sec. and 100 MBaud Wavelength: 1300 nm Bit error rate: better than 10-12 Connector type: ST Parity: even 9 bit data and 3 bit command 1.3.1.16.2. Data Format PP defined BIT MAP protocol.
1.3.1.17. VSB Interface
The VSB-TAXI module complies with the VSB standard. Maximum speed: Operation speed: 100 MBit/sec. 80 MBit/sec.
1.3.1.18. Film Processor Requirements
Film: polyester/paper Min. width of film: Max. width of film: Min. length of film: Max. length of film: Emulsion side: Film processing speed: Film buffer: Min. width of slit in processor: Entrance slit height from floor: Max. height from slit to top of processor: Max. distance from front side of film processor to first pair of rollers:
0.11 mm and 0.18 mm 400 mm 820 mm 250 mm 1200 mm up/down max. 200 cm/min. Min. 33 cm/min. Inside MAGNUM 850 mm 1035-1185 + 20 mm 300 mm
70 mm
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The film is always adjusted to the right side of the MAGNUM (rear view) In order to prevent polluted air from the processor from entering into the MAGNUM, the processor must take in air through the processor entrance slit - also when the processor is on standby. The processor should be placed in an office environment and must comply with all necessary environmental standards and requirements. Due to overall system noise, the processor should produce less than 45 dBA noise. The MAGNUM uses a 40 kHz ultra sound sensor at the exit slit. The film processor must not use any sensor that can interfere with this sensor.
1.3.1.18.1. Film Processor Interface Signals
Output from MAGNUM PROREQ: Processor request. Signal from ImageMaker MAGNUM indicating that a film is ready for the processor. This signal must reset PROFIN. Processor light mode. Indicates that the MAGNUM is turned off and the film processor can enter an energy conserving state. Processor select. Selects a media dependant way of processing the film.
PRLITE:
PROSEL:
Input to MAGNUM PROCON: Processor connected. Indicates whether the interface cable is connected to the ImageMaker MAGNUM and processor. Processor ready. Indicates whether the processor is switched on. Processor finished. The signal is high when the processor is ready to receive film. Goes low at SERVICE MANUAL
PRORDY:
PROFIN:
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PROREQ (and PROSEL) and high when the film leaves the entrance sensor of the processor. PROTMP: Processor temperature. Warning signal for the temperature in the processor. Processor level. Warning signal for the liquid level in the processor. Processor jam. Error signal if a film is jammed in the processor.
PROLEV:
PROJAM:
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ELECTRICAL CHARACTERISTICS
Symbol PROCON Condition Connected Not connected Power on Power off Processor ready Processor busy Temp. out of range Temperature ok Low liquid level Liquid level ok Jam in processor No jam REQUEST pulse period REQUEST to BUSY delay Min Typ 0.00 4.00 0.00 4.00 0.90 0.30 0.90 0.30 0.90 0.30 0.90 0.30 50 0 0.05 4.90 0.75 4.90 1.00 0.55 1.16 0.66 1.16 0.66 1.16 0.66 200 50 Max Units 1.50 5.00 1.50 5.00 2.00 0.75 2.00 0.75 2.00 0.75 2.00 0.75 1000 8000 V V V V V V V V V V V V ms ms
PRORDY
PROFIN
PROTMP
PROLEV
PROJAM
t t
REQ BUSY 10
tSEL1 50
PROSEL to PROFIN low0 ms PROSEL to PROFIN high 30 s 0 2 11 -1 0 10 12 0 0 200 13 1 mA mA(24V) V(20mA) V (0mA)
tSEL2 0 PROSEL Default processor Optional processor MAGNUM running MAGNUM sleeping
PRLITE
Connector Description The MAGNUM has a 25-pole sub-D female connector, located behind the lower right cabinet door (front view). The connector and cable shield is connected to the MAGNUM and the film processor frame. The film processor interface cable enters the MAGNUM through a hole in the bottom plate.
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Sequence Timing A communication sequence is as follows: the film has been exposed, cut, and ready to go to the processor. PROCON, PRORDY, and PROJAM signals are read. The sequence is interrupted in case of an error. The MAGNUM can be configured to wait if the processor issues PROFIN low (busy error) or issues either PROTMP or PROLEV warning. If so, the MAGNUM will enter a waiting/monitoring state for max. 20 minutes. When the processor is ready, the MAGNUM automatically resumes operation. If it does not get ready within 20 minutes, the MAGNUM leaves the waiting/monitoring state and goes to the next step in the sequence. PROTMP and PROLEV are read and a warning may be shown on the screen. PROFIN is read. If the processor is not ready, the sequence is interrupted.
This step in the sequence will only occur if the option is available on the processor: PROSEL is set depending on the media type. After a delay, PROFIN is monitored to see if the processor has switched to correct way of processing. PROREQ is set for 50-1000 ms. The film is conveyed to the processor. The film processor is ready (PROFIN high) to receive a new film when the end of the film reaches the film processor.
An error in the processor causing PROJAM to go high will not be detected until the next film. If a processor request (PROREQ) is issued, and a film does not reach the film processor, the film processor should not issue any alarms. The MAGNUM handles this situation.
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MAGNUM Error Messages Below is a list of MAGNUM error messages and the corresponding interface signals from the film processor. Film processor not ready. Check or reset film processor. PROFIN is low and PROJAM is low. Film processor temperature warning. PROTMP is high. Film processor liquid level warning. PROLEV is high. Film processor not connected. PROCON is high. Film processor not powered on. PRORDY is high. Film processor jam. PROJAM is high. Film processor selection failed. PROFIN stays low after PROSEL Waiting for film processor. PROFIN low or PROTMP/LEV high and MAGNUM has entered the waiting/monitoring state.
1.3.1.19. Film Processor Interface (Physical)
See engineering drawing CH9443 in chapter 10.4
1.3.1.20. Sensors and Motors
Sensors:
Hall elements, Ultra Sound sensors, Differential air pressure sensor (Vacuum), Mechanical micro sensor (Carriage), Mechanical IR sensors (Tight/Loop sensors, Cut/Snip sensor). Optical IR sensor (Film sensor in drum)
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Motors:
2- phase stepper motors (Conveyor Iris/Focus), DC motors (Register/Cutter/W. Valve/Magazine), Brushless DC motor (Spinner), 5 phase stepper motor (Carriage).
1.3.1.20.1. General Requirements All I/O
On PCB all inputs and outputs on the Scanner Control are protected against static electricity, up to 2 kV.
1.3.1.21. DC Voltages
Output from DC PSU
+24Vdc, 8A
+5Vdc, +12Vdc, -12Vdc is generated by DC/DC converters on the PGM and SCM connector boards.
1.3.1.21.1. Bitbus Modules
Module groundplane is neutral for the DC voltages. DC voltages: + 24 V +/- 10%, TBD A +/- 12 V +/- 10%, TBD A + 5 V +/- 3%, TBD A
1.3.1.22. Isolation
All signals between modules are optically isolated.
1.3.1.23. Operation Environment (The room where the machine is installed)
With ventilation box: Temperature range: Relative humidity: 20C +/- 2C 50% +/- 5% RH
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With climate control: Temperature range: Relative humidity: 15C to 35C noncondensing 20% - 80% RH noncondensing
1.3.1.23.1. Bitbus Modules
Normal operation: Temperature range: Relative humidity: Optional operation: Temperature range: Relative humidity: 20C to 30C 50% +/- 10% RH
15C to 45C 20% - 80% RH
1.3.1.24. Electrical Environment
EMC susceptibility:
According to PIN-ADM-07-12 "Environmental Requirements"
1.3.1.25. Regulations
According to PIN-ADM-0710 "Regulatory Requirements".
1.3.1.26. EMC
Complies with the following regulations:

FCC part 15 subp. J Class B VDE 0871/6.78 Class B DS5101 P1
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1.3.2. Explanation of Terms
PP RIP TAXI VSB VTM VME SCM PGM BTM BBM PCI EISA
= = = = = = = = = = = =
Purup Prepress Raster Image Processor Transparent Asynchronous Xmitter Receicer Interface VME Subsystem Bus VSB TAXI Module Versa Module Europe Scanner Control Module Pixel Generator Module Bitbus TAXI Module BitBus Master Peripheral Component Interconnect Extended Industrial Standard Architecture
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1.3.3. System Configuration
In the system configuration the MAGNUM is a slave machine, and it only contains electronics for machine control, communication, and software. Bitmap data are received from a Raster Image Processor which is connected to a network with PC's, MAC's, or workstations (see figure 1.3.3.)
RS 232
Workstation (Mac)
Macintosh running StandardPageTool communication software and Purup Terminal (PS-Link console)
Purup PS-Link
Optical Link
Workstation (Mac)
MAGNUM
Workstation PC
PC Operator console running DOS and Purup ImageMaker software
Purup ImageMaker MAGNUM
Workstation PC
Figure 1.3.3
System Configuration:
1.3.4. Work Flow
Text and illustrations are made in an application program, e.g. Aldus Freehand, Adobe Illustrator, etc. Images can be scanned in and collected e.g. in Quark Express or PageMaker where the entire page can be composed. Furthermore, these programs can add register marks or cutting marks and perform colour separation.
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From these application programs PostScript files are generated, and by means of a montage program, e.g Standard Page Tool, these applications or more colours from the same application can be placed on the same film, and thus the entire drum format can be used in the MAGNUM. The montage file with montage information and the name of the placed PostScript files are transmitted together with the PostScript files to the Raster Image Processor, which generates a bitmap and transmits it to the MAGNUM.
1.3.5. Main Functions
1.3.5.1. Film Magazine
The film magazine has three separate compartments that can contain one roll of film or polyester plate each. The magazine is driven by a motor, "the magazine motor". When the wanted film has been chosen, the magazine is positioned automatically. Due to the coding of the individual compartments in the magazine, the machine always knows which film/paper roll is in use. A roller mounted on the loader frame outside the magazine pulls the film/paper out of the magazine. A separate motor called "shaft motor" drives this roller. When the magazine has been positioned, one of the rollers in the magazine moves up to the roller on the loader frame, and the film/paper is positioned between the two rollers. When the shaft motor is activated, the film/paper is pulled out of the magazine.
1.3.5.2. Cutting System
A motor/belt-driven cutting wheel cuts the recording mediumwhen exposed. This cutting wheel, which is mounted on a carriage, moves along a cutting edge. The carriage of the cutting wheel is fixed to a toothed belt. When the "cutting motor" starts, the carriage with the cutting wheel moves from left to right and cuts the film/plate.
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The film/paper then falls into the conveyor and activates the cut sensor, indicating film/plate is cut. After a cut the carriage returns to the media load position. This is the "home position", and a sensor indicates when it has been reached. 1.3.5.3. Loader System The function of the loader system is to grip the film/plate when the shaft motor pulls it out of the magazine. The "belt motor", which drives the loader, pulls the film/plate down into the drum synchronously with the shaft motor. After exposure and when the film/plate has been cut, the bottom pair of rollers in the loader still hold the film/plate. When the belt motor reverses the direction of revolution, the film/plate is conveyed out of the drum to an on-line processor. 1.3.5.4. Drum The drum has several sub-assemblies: 1) 2) 3) 4) The linear system. The spinner system. The register system. The vacuum system.
1)
The linear system consists of a full casted iron balk, mounted with a carriage and a screw spindle. A stepper motor, the "spindle motor", rotates the spindle, moving the carriage linearly along the drum. The linear system is an integrated part that is mounted into the drum. Bellows cover the spindle system to prevent dust from entering the system. Zero point positioning and maximum traverse of the carriage are controlled by sensors.
2)
The spinner system consists of a spinner axle onto which the rotating part of an encoder the rotating optics, and a rotor for the spinner motor are mounted. The spinner system is mounted in a suspension cylinder which is fixed to the carriage. The stator of the spinner motor is also mounted in this suspension cylinder.
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Around the suspension cylinder to the spinner a guide is mounted which guides the film down into and around inside the drum. 3) The register system consists of separate register units which can be placed individually. They are available with different punch types so that it is possible to combine them and get different register systems standards. The punches in the register units are driven by a motor on which a sensor is mounted, indicating whether the punch is up or down. The vacuum system has two functions: to suck the film to the drum, and to remove the small pieces of punched-out film that. The system consists of a vacuum pump, a vacuum valve, and a container for "waste". The vacuum pump runs constantly to obtain maximal suction when the film/paper is sucked over to the drum; a vacuum valve changes between different channels to make a vacuum in the drum and to suck the waste into the container when the film is in the drum. The pump only draws air while the film is loaded.
4)
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1.3.5.5. Optical Housing
The optical housing holds the iris and focus system and collimating optics. The iris system will cut the laser beam diameter to the correct spot size on the exposure media with reference to the selected output resolution. The focus system will adjust the focal point on the exposure media with reference to the selected media. The optical fibre is connected directly to the optical housing, carrying the laser beam to the optical housing.
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1.3.5.6. Laser
The MAGNUM is available with two laser variants, an argon ion gas laser and an infrared diode laser. Irrespective of the laser type chosen, the main purpose is to generate a well-defined beam which can be switched on and off synchronously with the spinner speed of revolution and the linear motion of the carriage. The beam is led from the laser by an optical fibre to the optical housing.
1.3.5.7. Climate Control
As an option, the MAGNUM is available with climate control. The climate control unit is placed at the right side of the machine and ensures constant temperature and air humidity around the film being exposed. Air is recirculated and filtrated internally in the machine, and the same air is thus regulated as regards temperature and humidity. As no new air enters the MAGNUM, it is possible to prevent dust from entering the machine. Note: If the machine has no climate control, an internal ventilation system ensures cooling of the internal parts of the machine. Operation environment must comply with Purup Prepress specifications.
1.3.5.8. Electronic Modules
The electronic modules in the MAGNUM control the various motors and receive the messages from sensors and encoders. Furthermore, they handle communication between the PS-Link and the MAGNUM and process the bitmap data transmitted from the PS-Link.
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PURUP IMAGEMAKER MAGNUM PREINSTALLATION
PAGE 1.4.1
1.4. Preinstallation
On the following pages you will find extracts from the Preinstallation manual for the Purup ImageMaker MAGNUM.
Go to Preinstallation Manual
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PURUP IMAGEMAKER MAGNUM INSTALLATION
PAGE 1.5.1
1.5. Installation
This chapter describes in practical steps how the MAGNUM is installed.
1.5.1. Site Preparations
In order to accomplish successful installation and initial testing of the MAGNUM, certain steps must be taken by the customer and the sales organisation.
1.5.2. Pre-installation Responsibilities
Referring to chapter 1.4 Preinstallation in this manual, the customer is responsible for the following on-site preparation tasks before the MAGNUM is installed by a service engineer trained by Purup Prepress. These customer responsibilities are reviewed here in a short form enabling the Purup Prepress Service Engineer to know what the customer is expected to do before the installation can be carried out.
1.5.3. Electrical Distributions
MAGNUM The Purup ImageMaker must have a computer grade isolated electrical line directly from the main distribution board with either 2 or 3 separate phases, neutral and ground, depending on how the MAGNUM is configured. Phase 1 Phase 2 Phase 3 is used for the main power supply. is used for the Argon Ion laser, if included. is used for the Climate Control unit, if included.
This means that a MAGNUM with diode laser and no climate control unit will be a 1-phase machine! Example: MAGNUM with Argon laser and climate control: P1 = Main voltage P2 = Argon laser P3 = Climate control If no neutral is present, a Delta to Star transformation must be made as described in the Pre-installation Manual, chapter 1.4.
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The nominal mains supply voltage between phase and neutral for the MAGNUM can be either/or: a) b) Note: 1, 2 or 3 x 220 to 240 VAC + 6% / - 10% RMS 1, 2 or 3 x 100 to 120 VAC +/- 10% RMS
The pull-up time must not exceed 20 msec for the nominal mains voltage!
The fuse requirement is 16 Amps/phase at the mains inlet, for both 110/220 VAC. 220V: The main power cable/cables supplied with the MAGNUM must be fitted with industrial plugs when used/connected into wall installations. The 3 power cables fitted with the US standard plug (Nema 5-15P) must be connected into wall installations. 50 or 60 Hz +/- 2.5%
110V:
Frequency:
The resistance in the earth wire must be less than 10 Ohm, and the earth wire must be connected to the earthing terminal of each receptacle and returned directly to an earthing point supporting only the Purup Prepress equipment. Conduit is NOT an acceptable ground path! Note: All work regarding the electric installation is to be carried out by a local certified electrician in order to comply with local/national regulations.
1.5.4. Environmental Requirements
Depending on the configuration of the MAGNUM, the environment, in which the MAGNUM is installed, has to be controlled by an air-conditioning system. The MAGNUM can be supplied with a climate control system (option) that will keep the temperature inside the machine at 22oC +/- 2oC, and the relative humidity (RH) at 44%, +/- 5%. Note: This climate control unit will only ensure that the environment around the exposure area is kept PURUP PREPRESS A/S
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optimal during every exposure. It will still be necessary to have environmental control outside the machine in order to secure the stability of all the system hardware. If the MAGNUM does not have an air-conditioning system, it is necessary to install an air-conditioning system in the room, in which the MAGNUM is installed, in order to provide the ideal working conditions for the MAGNUM. It is not allowed nor recommended having an on-line processor installed in the same room as the Purup Prepress equipment, unless the processor has a scavenger fan (exhaust) built into the cabinet that removes corrosive gases, eg from developing and fixing baths. If the building lies next to a rail road or a road with heavy traffic there is a risk that the building, and thus the floor, under certain circumstances may vibrate and affect the quality of the scanned image.
1.5.5. Working Area
The recommended size of the work area will be: 16 m2 work area (4m x 4m), with On-Line processor. See drawing overleaf fig. 1.5.5.1
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CLEARANCE DISTANCES FOR PIM WITH DEVELOPER UNIT Note: minimum door width 800 mm (32")
When
Fig. 1.5.5.1 installing the Magnum with Climate Control Unit, there are the following two possibilities:
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a.
Manual water feed. The hose goes into a water container. The hose bend should be max. 350 mm above the floor. The container (15 litres) is supplied with the Magnum. b .
Automatic water feed. The hose goes to a fixed outlet. The height of the outlet should be 250 mm (max. 350 mm) above the floor. The outlet pipe should have a diameter of minimum 40mm, allowing air to pass between the hose and the pipe. The connection hose is connected to the spigot.
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1.5.6. Pre-installation Verification
Before unpacking, inspecting or installing the MAGNUM, the service engineer must verify that the following requirements are met: 1. 2. 3. 4. 5. 6. 1, 2 to 3 separate one-phase 110/220 VAC lines, OK? An isolated earthing of dedicated line, OK? Main fuses rated for 16 Amps, OK? Correct earthing and voltages at receptacle, OK? Wall installations equipped with industrial plugs (220V)? If you have a MAGNUM without climate control, can the customer's air-conditioning and humidifier provide proper environment? (See item 1.5.4. Environmental Requirements) All shipping containers must be checked for transport damages (see shock hazard labels). Verify upon delivery of the equipment at the customer's address that the equipment has been placed in proper storage immediately after arrival, until unpacking can take place. This means that the equipment must be stored indoors, in a controlled environment, and kept away from water, moisture, and chemical influence, and also be protected against mechanical impact and heavy loading on top. Note: It must be pointed out to you that it is your responsibility to ensure that all installation requirements are complied with and in accordance with local laws and regulations, the requirements stated in this manual, and the Purup Prepress data sheets. If, however, above conditions are not fulfilled, explain to the customer what the discrepancies are and inform your service manager.
7.
8.
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IF THE REQUIREMENTS FOR THE PURUP PREPRESS EQUIPMENT ARE NOT COMPLIED WITH, IT WILL VOID THE WARRANTY.
1.5.7. Installation Procedure
1.
Open boxes, remove contents, and check all equipment against order forms and shipping documents. Visually inspect unpacked items for physical damage or corrosion, and check shock hazard labels. Place the MAGNUM in the prepress room in accordance with the layout prepared by the customer, with reference to chapter 1.4 Preinstallation. Adjust the height of the machine feet so there is a clearance of approx. 2.5 to 3.5 cm from the floor to the lowest part of the MAGNUM frame. Note: Make sure that the MAGNUM is in good level!
2.
3.
4.
The transport security in the Purup ImageMaker Magnum consists of two parts: 1. The drum is fixed to vibration dampers and 2. The spindle is fixed by a fitting Vibration Dampers The two transport security screws under the bottom panel should not be loosened.
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The screws under the four sets of vibration dampers should be loosened so that there is 2mm space between the top of the washer to the bottom of the chassis. (You may have to use a key to loosen the screws). There is easy access to the two front screws. To loosen the rear left screw you should dismount the lattice for the DC distribution board. The right rear screw can be accessed though the CCU air channel (use a ratchet wrench).
Note:
If you fail to loosen the screws, the vibration dampers have no effect causing a decreased screen quality. No wires should be placed between the foam and the drum as this would reduce the effect of the dampers.
Note:
Transport Security of Spindle System
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Follow the procedure below: Unlock the carriage with screw M6x20 at item 4. Dismount transport fitting (item 3) with screw M6x30 at item 5.
Mount the screw M6x20 (item 4) from the transport fitting in item 1. Fix the spindle nut to the carriage at item 2 by means of screw M6x30 from item 5. Remember to re-tighten the four transport security screws and mount the transport fitting for the spindle system when the machine is to be moved.
5.
Place the processor at the back of the Magnum. Be careful not to push the processor too hard up against the Magnum (the rear plate must not be bent) as vibrations from the processor may affect the film quality. Verify that the interconnections between the Magnum and the processor are ok (communication cable and SERVICE MANUAL
6.
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earthing). 7. Place the PC within the specified cable length of the MAGNUM, and verify that the bitbus cable and power cables can be routed in a safe way. Connect the FDDI optical fibre cable between the MAGNUM and the PS-Link, and verify that the optical cable is routed in a safe way and cannot be damaged. If the CCU has automatic water feed, connect the connecting hose (6) to the spigot. If it is a new spigot, you should tap off some water in a container to remove any remains of teflon tape, etc. Lead the hose to the outlet.
8.
9.
Note:
The outlet should have a height of max. 350 mm. The diameter should be sufficiently large for air to pass (9) between the hose and the outlet. The PURUP PREPRESS A/S
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machine should be placed so that the CCU can be opened freely and so that the drain hose is not forced up of the outlet. Note: The magnet valve is only open for 5 seconds per minute when water supply is required in the CCU. A flow limiter of 1 litre per minute is connected to the water supply. This gives a maximum flow of approx. 0.08 litres per minute when water is supplied. When a new system is started there is no water in the container, and you should fill approx. 1 litre into the container when starting up. The control will keep the water supply at approx. 3.7 litres.
Note:
10.
Go through the Service check list, item 1.5.8 before doing anything else on the equipment. Copy all the test montages on the MAGNUM test montage diskette to an empty folder on the Macintosh running SPT. Open the test films 1201, 1202, and 1203, expose them one by one, evaluate them and determine the exposure performance of the MAGNUM. MAGNUM Test Film 1201 Linearity - Scaling - Angularity. MAGNUM Test Film 1202 Screening Test. MAGNUM Test Film 1203 Repeatability. (see chapter 2.5 for information about evaluation of the individual test montages)
11.
12.
Fill in the "Installation Acceptance Test Form" (item 1.5.9), with the related installation data. Sign the "Installation Acceptance Test Form" yourself, and make sure that the customer sign it as well.
13.
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1.5.8. Service Check List
This service check list must be followed point by point when the MAGNUM is installed, and the relevant paragraphs must be followed during service visits.
1.5.8.1. Basic Check
1. 2. 3.
Remove transport security from drum/carriage. Verify that the service key is in position ON. Power up the MAGNUM by pressing the soft start button.
1.5.8.1.1. PC
1. 2.
Check software version - latest version should be loaded. Check configuration with print out from Purup Prepress Production. Remember to change the print out in case of configuration change. Reboot and run a function test if found necessary.
3.
1.5.8.1.2. Cooling System
Air Condition 1. Check the circuit breaker function. Note: The compressor should start and stop alternately during start up of the MAGNUM. The compressor should run constantly after 15 minutes to two hours. If the MAGNUM doors have been open for some time, the compressors should start and stop alternately again.
2.
Check temperature and air humidity on top of the tube end in the right side of the climate-controlled compartment. Temperature Air humidity 22 50 23 47 24 44 25 38 26 degrees Celsius +/- 5% RH
Temperature should thus be 22 to 26 degrees Celsius. Air humidity depends on the temperature, see the table.
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3.
Check the filters inside the door panels.
1.5.8.1.3. Ventilation
1. 2.
Check the fan rotation Check temperature and air humidity on top of the ventilation channels in the right and left sides of the climate-controlled compartment. If the film specifications are not kept, temperature and humidity should meet the requirements from 1.3.1.22. An ambient temperature above 30 degrees Celsius can cause problems with mechanics and electronics. The PC must be set to give an alarm at 28C, see Configuration - Miscellaneous.
1.5.8.1.4. Mains Power
1. 2. 3. 4.
Check earth connection. Is there a certificate? Check PC supply from the MAGNUM. Check mains voltages. Check that the MAGNUM has its own electrical line directly from the main distribution board.
1.5.8.1.5. Power Supply Voltages
1.
Check +5 V, +12 V, +24 V, on the connector boards.
1.5.8.2. Loader System
1. 2.
Check that the chassis frame isfirmly fixed to the drum. Estimate loader frame level as follows: a. Run a maximum format film. Bend the film in the middle in drum direction. The two cut edges should
20"
Cut Edges 26" Fold
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be parallel. b. Run a dump film. Check that the film is loaded correctly into the drum, between manifold guide and film guide.
3. 4. 5. 6.
Check that no belt catches the mechanical parts. Check that all belts are positioned correctly. Estimate whether all belts have the same tension. Check loop, tight, film cut, and snip sensors. Activate the sensors manually. Check that the snip sensor is positioned correctly. Check that the film is tightened before cut during film dump.
7. 8.
1.5.8.3. Cutting System
1.
Estimate cut quality in a microscope. The cut should be clean. Run a "CUT SEQUENCE" and check that the cutting wheel runs from the left to the right and back, without any mechanical collisions with the end-stop flanges. Check all three magazine covers. They should not stick when opened but shut tight. Check for slackness in rotation direction, tighten the belt if necessary. Note: Moderate slackness is allowed on the MAGNUM.
2.
1.5.8.4. Magazine
1.
2.
3.
Check feed rollers. a. b. Should run freely without film Distance between rolls left, centre, right: Use a small piece of film 1 to 2 cm wide. It must not be possible to push the film between the rollers PURUP PREPRESS A/S
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without them being activated. 4. Make a function test from the Service program.
1.5.8.5. Processor
1.
Must give acceptable density. Try with a film exposed with daylight. Check for pin holes. Check that chemicals are according to film type, temperature, and timing.
2. 3.
1.5.8.6. Carriage System
1.
Verify maximum exposed film format without hitting the right end stop after a function test of the carriage. Note: Distance is 820 mm + left end point in mm.
2.
Check that carriage system inclusive bellows does not catchany stationary mechanical parts. Check the film jam switches cause carriage stop. Make a function test from the Service program.
3. 4.
1.5.8.7. Register System
1. 2.
Does register fit to customer register? Make a function test from the Service program.
1.5.8.8. Spinner System
1.
Check speed:
12,000 24,000
+/- 5 rpm. +/- 10 rpm.
2.
Make a function test from the Service program.
1.5.8.9. Optical System
1. 2. 3.
Is the fibre fixed properly in the optical housing? Make a function test of the Iris from the Service program. If necessary make a function test of the Focus system in
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the Service program.
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1.5.8.10. Bitbus System
1.
Check that there is a "P" in the display on SCM and PGM after power up. Make a loop-back test from RIP. Check bitbus connection to every single module by means of the BBM program. Download INIT Bist from the Main program to test the SCMs and PGM/BTM hardware.
2. 3.
4.
1.5.8.11. Laser
Argon-Ion Laser 1. 2. 3. 4. Check circuit breaker function on AC box. Check LEDs in laser power supply (all on). Check that laser ignites after approx. 20 to 30 sec. Check tube current: 4.30 A on power supply, in light mode. Check the laser fan and filter on laser unit. Check modulator driver supply voltage: 30 Vdc and +5V dc +/- 10% when machine is running. Run density film, and generate ideal Start and Power jump values, from the User program (version 4.0 only).
5. 6.
7.
IR Laser Diode 1. Check that it is alight with infrared sensitive paper in the drum. Display the reference temperature of the diode by displaying PGM parameter no. 4 (should be 750). Run a density film, and generate ideal Start and Power jump values.
2.
3.
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1.5.8.12. Safety System
1.
Check that the machine completes a normal start up with key in normal position and all doors to the machine closed. Check that all motors stop and voltage to the modulator driver is disconnected if a door is opened. Select SPECIAL, SECURITY SYSTEM, in the Service program, verify that all check points correspond to the status of the machine and try opening doors to make a change in the Security System.
2.
3.
1.5.8.13. Vacuum System
1.
Make a vacuum system function test from the Service program. Verify that the vacuum can hold both a minimum and a maximum film size in the drum and verify that the film is in full contact with the drum surface.
2.
Return to item 1.5.7, Installation Procedure, and continue with point 8. 3. Verify that the air cushion system works, meaning there is no dirt in the air injection holes, air comes out and the vacuum valve is positioned without errors.
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1.5.9. Installation Acceptance Test Form
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PURUP IMAGEMAKER MAGNUM TOOLS
PAGE 1.6.1
1.6. Tools
1.6.1. Personal Tools
In order to service the machine you need the following tools: Philips Scopemeter, PM 97 (measuring, troubleshooting) Peak, Stand Microscope, 75x (evaluating exposure quality) Allen keys, 1.5 to 4 mm,T-handle Allen keys, 1.5 to 10 mm, Bacho 9770 Pozi Screwdrivers, Vera PZ 1 and PZ 2 Combination wrench, 24 mm (for magazine) Plastic hammer, Vera 101/1/22.
Furthermore, you need nippers, wire cutter and wire stripper.
1.6.2. Special Tools
Purup ImageMaker Alignment kit. (Necessary for aligning the vital parts of the mechanics and optics.) Order no. 8800017+8800018 Dummy spinner, for alignment of the MAGNUM Linear system and PSD pipe for MAGNUM dummy spiinner to adjust the optical housing. Dentist's mirror, Stahlwille 12921-30 Flexmagnet, Stahlwille 12600/500
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PURUP IMAGEMAKER MAGNUM SERVICE INTERFACE
PAGE 2.1.1
2.
Machine Operation, Test, Troubleshooting and Configuration
2.1. Purup ImageMaker Service Interface
2.1.1. The ImageMaker Service Program is designed specially for General Introduction Purup Prepress service engineers. The program contains a number of commands designed for testing and adjusting electronic modules and mechanical parts of the ImageMaker. How to Get Access to the Service Program The Service program can be accessed in two ways: from the Main Menu or using the SERVICE PROGRAM command in the User Program. Password As the Service Program gives you access to commands that control vital parameters, the program is password-protected to make sure that users do not accidentally change parameter settings.
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The password is universal for all ImageMaker machines and cannot be changed for the individual machine. The structure of the password is very simple as it is based upon the actual date of the month, multiplied by 11. Example: the password for the 10th is: (10 X 11 = 110) the password for the 22nd is: (22 X 11 = 242) Note: In your own interest, do not reveal the structure of the password protection to your clients!
Nodes Throughout the manual you will find references to so-called "nodes" or "node adresses". "Node" or "node adress" refer to the adress of a module on the Bitbus network. Node adresses: PGM: BTM: SC4: SC5: SC6: SC7: BBM:
1 3 4 5 6 7 255
These nodes are also used when generating error codes.
Survey of Menus in the Service Program, version 6.02 Medium, Status, and Help are identical with User Program.
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CONTROL SPECIAL CUMMUN EXPOSURE LOADER MAGAZINE REGISTER CUTTER FOCUS IRIS CARRIAGE VACUUM PROCESSOR LASER SPINNER SECURITY
MEDIUM
STATUS
EXIT Reboot Main program Turn off Restart Installation User Program RIP Offline RIP Online F9 F10 F8 s-F1 s-F2
HELP
All menus in this chapter are based on the 6.03 version.
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2.1.2. Control Menu
The Control menu contains a number of commands which control specific sub-systems in the Purup ImageMaker MAGNUM. Examples of such sub-systems are spinner, laser, vacuum etc. Each of the commands contains a number of sub-commands which execute specific operations.
2.1.2.1. Special
The Special command contains two items: Parameters and US sensor testvalues:
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2.1.2.1.1. Parameters
Operation:
The PARAMETER command opens a dialog box which allow you to display or change the SCM and PGM parameters. Select the wanted option and click OK, then a new dialog box appears
2.1.2.1.2. US Sensor Test Values
Operation:
The US SENSOR TESTVALUES command displays all testvalues from the ultrasound and IR sensors None Machine limit: Low limit: Measured value: Sensor minimum value Minimum value used in test Must exceed "Low limit"
Input: Ouptut:
Notes:
This command can be used to verify the function of the US/IR sensors with or without film/paper.
An example of the values is: US-Sensor 1: IR-Sensor 1: US-Sensor 6: US-Sensor 7: IR-Sensor 3: 1691 21 1763 1712 20 3382 11 3527 3424 10 500 0 500 500 0
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2.1.2.2. Communication
The Communication command is divided into three subcommands: Taxi, Bitbus and Filmmeter.
2.1.2.2.1. TAXI
The Taxi system controls communication between the PS-Link and the ImageMaker via a fiber optical link.
All commands in the TAXI menu are primarily meant for R&D test purposes. For further information on these commands, please refer to the TAXI protocol specifications.
2.1.2.2.2. BITBUS
The BITBUS systems controls communication between the ImageMaker PC and the ImageMaker via an RS 422 serial communication line.
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OPEN SEC Operation: The OPEN SEC command switches off the safety loop on the module specified in the dialog box. NODE: Value range: 1; 3; 4; 5; 6; Note: Output data: Notes: The value "0" switches off all safety loops.
Input data:
None If the safety loop is switched off on just a single module, the 24/48 Voltage is taken off the entire machine!
CLOSE SEC Operation: The CLOSE SEC command switches on the safety loop on the module specified in the dialog box. NODE: Value range: 1; 3; 4; 5; 6; Note: The value "0" switches on all safety loops. None
Input data:
Output data: Notes:
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SET POLLINT Operation: The SET POLLINT command sets the "poll interval", that is the interval with which the masterboard collects data from the various modules. POLLINT: Value range: 1 - 200 Unit: 62 mS None Normal value: 8 (= 496 mS)
Input data: Output data: Notes: ENABLE WD Operation:
Input data:
Output data: Notes:
The ENABLE WD command switches on the "watch dog" on the module specified in the dialog box. NODE: Value range: 1; 3; 4; 5; 6 Note: The value "0" switches on all modules. None The 24/48 Voltage system is switched off unless the "watch dog" is activated on all modules!
POLL NODE Operation: The POLLNODE command makes the Master board poll (= look for data) from the module specified in the dialog box. NODE: Value range: 1; 3; 4; 5; 6 None The POLL NODE command remains active until the NO POLL command is activated!
Input data: Output data: Notes:
NOPOLL NODE Operation: The NOPOLL NODE command makes the masterboard stop polling (= stop requesting data) from the module specified in the dialog box. NODE: 1; 3; 4; 5; 6 None
Input data: Output data:
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Notes:
The NO POLL command remains active until the POLL NODE command is activated!
A/D CONVERSION Operation: The A/D CONVERSION command makes an Analog-to-Digital conversion on the module and channel specified in the dialog box. NODE: Value range: 1; 4; 5; 6 (See also: 2.1.1) CHANNEL: Value range: 1 - 50 (See also: 7.2) FILTER: Value range: 1 - 15; Recommended value: 15 (the FILTER parameter defines the number of readings on which each conversion is based) SENSOR TYPE: Value range: 1 - 3 (1=Ultra Sonic, 2=Hall, 3=Normal (=all other types) Value range: 0 - 4095 (how to convert this value to voltage depends on the selected module and channel) SENSOR TYPE: the value "2" (Hall) can also be used on channels of type "3" (Normal) TBD TBD
Input data:
Output data:
Notes:
ENABLE TIMELOG STORE TIMELOG
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2.1.2.2.3. FILMMETER
FILMMETER ID: FILMMETER COUNTER LOV: FILMMETER COUNTER HIGH: FILMMETER TEST 1: FILMMETER TEST 2:
TBD TBD TBD TBD TBD
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2.1.2.3. Exposure
The EXPOSURE command contains a number of commands for controlling the exposure of films.
Offset Film The Offset Film command is used during adjustment of offset counters, Unload before cut, Film load, etc. For further information please refer to the Adjustment chapter, 2.8 in this manual.
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CONT EXP ON Operation: The CONT EXP ON command makes the ImageMaker expose all jobs from the RIP on the same film. The film is not unloaded until the CONT EXP OFF command is activated. None None This command is used when exposing test film 1203, repeatability.
CONT EXP OFF Operation: The CONT EXP OFF command makes the ImageMaker stop continuous exposure by deactivating the CONT EXP ON command. None None See CONT EXP ON for further information.
START EXPOSURE Operation: The START EXPOSURE command starts a dummy job. Film is loaded into the drum but not exposed. The spinner runs in "run/wait" mode. This command can simulate an exposure when no RIP is connected to the ImageMaker. RESOLUTION: Value range: 5 = 5 m/4840 dpi (not implemented) 10 = 10 m/2540 dpi 20 = 20 m/1270 dpi OB/RE: Value range: 1 = obverse 2 = reverse POS/NEG: Value range: 1 = negative 2 = positive PURUP PREPRESS A/S
Input data:
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Output data: Notes:
FILM TYPE: Value range: 1 - 10 Defines which film type to use. FILM ROLL: Value range: 0 - 3; 0= default magazine Defines which film roll magazine to use. REGISTER TYPE: Value range: 1 - 10 Defines which punch register type to use. None You can only quit the START EXPOSURE command by activating the STOP EXPOSURE command. "Test job" is displayed in the "JOB NAME" field in the "JOB STATUS" window.
STOP EXPOSURE Operation: The STOP EXPOSURE command is used to quit the START EXPOSURE command. None None See "START EXPOSURE" for further information.
SET RESOLUTION TBD
SET OFFSET Operation: The SET OFFSET command is used to move the horizontal start of scan downwards or upwards in the drum during exposure OFFSET: Value range: 0 - 40000 Unit: 20 m None The offset value stated in this dialogue box replaces the normal offset value indicated in the Configuration program. SERVICE MANUAL
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The new offset value is only valid for the exposure in question, i.e. the new value has to be entered in chapter 2.3.3.1 to take effect on future exposures. SET RS-LINES Operation: The SET RS-LINES command defines the number of run/stop scan lines during exposure. None None The RS-lines value stated in this dialogue box replaces the normal RS-lines value indicated in the Configuration program. The new RS-lines value is only valid for the exposure in question. This command is primarily designed for test in R&D, or when optimizing the data synchronization to other RIPs.
OPEN BITMAP Operation: The OPEN BITMAP command opens the bitmap channel from BTM to PGM and set the data transport to exposure mode. When the bitmap channel is open, the spindle cannot run in express mode. PO-NEG: Value range: 0 = positive = normal bitmap data 1 = negative = inverted bitmap data Defines whether the bitmap channel is opened in positive or in negative mode. Negative = inverted bitmap data. RESOLUTION: Value range: 5 = 5 m/4840 dpi (not implemented) 10 = 10 m/2540 dpi 20 = 20 m/1270 dpi FRAME: Value range: 0 = White PURUP PREPRESS A/S
Input data:
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Output data: Notes:
1 = Black Defines whether the laser is ON or OFF outside the exposure area. DIRECT: Value range: 0 = Obverse 1 = Reverse None This command is primarily designed for test in R&D.
CLOSE BITMAP Operation: The CLOSE BITMAP command closes the bitmap channel from BTM til PGM and set the data transport back to normal mode. None None None
Input data: Output data: Notes: DEMO EXPOSE Operation: Input data: Output data: Notes:
Select film size (min/max.). Select film roll (1, 2, or3) None This function is usually used during demos or during an exhibition. It can also be used to check the stability of the loader system after service.
CONT. MACH. TEST Operation: Input data: Output data: Notes:
Selectable from the menu. The ImageMaker exits to Main program or turns off. This function will exercise the Carriage, Cutter, Register and vacuum valve with reference to the input data. This function is used during test of the climate control system.
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BTM DISABLE BTM ENABLE 2.1.2.4. Loader
TBD TBD
The LOADER command contains a number of commands for controlling the loading of film.
TURN ROLLER MOTOR Operation: The TURN ROLLER MOTOR command makes the roller motor revolve in the direction and at the speed specified in the dialogue box. DIRECTION: Value range: 1 (=forwards) 0 (=backwards) (Forwards is feeding film into the drum) LENGTH: Value range: 0 - 32000 Unit: 100 = one revolution (60 mm/2.5 inches) SPEED: Value range: 200 - 500 Normal speed: 350 200 = max. speed; 500 = min. speed None WARNING!: This routine is fully manual and without any control.
Input data:
Note: Output data: Notes:
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TURN CONVEYOR MOTOR Operation: The TURN CONVEYOR MOTOR command makes the conveyer motor revolve in the direction and at the speed specified in the dialogue box. DIRECTION: Value range: 1 =forwards; 0 =backwards (Forwards is feeding film into the drum) LENGTH: Value range: 0 - 32000 Unit: 100 = one revolution (60 mm/2.5 inches) SPEED: Value range: 300 - 600 Normal speed: 350 Note: 200 = max. speed; 600 = min. speed None WARNING!: This routine is fully manual and without any control.
Input data:
Output data: Notes:
LOAD FILM MAX Operation: The LOAD FILM MAX command loads a film into the drum from the magazine in position. None None Film/paper can be removed with SPECIAL + FILM PLACEMENT + FIND&EJECT FILM.
LOAD FILM MID Operation: The LOAD FILM MID commands loads a film into the drum from the magazine in position. None None Film/paper can be removed with SPECIAL + FILM PLACEMENT + SERVICE MANUAL
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FIND&EJECT FILM. LOAD FILM MIN Operation: The LOAD FILM MIN commands loads a film into the drum from the magazine in position. None None Film/paper can be removed with SPECIAL + FILM PLACEMENT + FIND&EJECT FILM.
UNLOAD FILM Operation: The UNLOAD FILM command rewinds a film approximately 70 mm/ 2.75 inches. SPEED: Value range: 200 - 600 Normal speed: 350 300 = 75mm/3 in. per second Note: 200 = max. speed; 600 = min. speed None The film will be loaded back into the magazine.
Input data:
Output data: Notes:
TIGHT FILM Operation: Input data: Output data: Notes: The TIGHT FILM command tightens the film before it is cut. None None If you have a film loaded, this function can test wether the tight sensor is working.
FILM TO CASS/PROC Operation: The FILM TO CASS/PROC command activates the conveyer and feeds the film into the cassette or the film processor. None PURUP PREPRESS A/S
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Output data: Notes: Warning:
None The motor in the pick-up cassette is started automatically. The film must be cut before activating this function. TBD TBD
FTEST US/IR FTEST US 7 FIND FILM
The FIND FILM command contains three sub-commands for finding and ejecting a film from various locations in the machine. FIND IN LOADER Operation: The FIND IN LOADER command checks for film in the belt and loader system. The result of the check is displayed as a status message in a separate dialog box. None STATUS: Value range: 0 - 7 0 = no film found; 1 - 7 = film found 1: film found at 2: 3: 4: 5: 6: 7: In case of error situation, eg. a film jam, the system does not display a status message but an error code.
Notes:
FIND IN DRUM Operation: The FIND IN DRUM command checks for film in the drum. The result of the check is displayed as a status message in a separate dialog box. None SERVICE MANUAL
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Output data:
Notes:
STATUS: Value range: 0; 9 - 14 0 = no film found; 9 - 14 = film found 9: only film at US1 10 - 11: film in drum - film not cut 12 - 14: film in drum - film is cut The carriage must be positioned at the zero point, or you will always find a film in the drum. In case of error situation, eg. a film jam, the system does not display a status message but an error code.
FIND IN CONVEYOR Operation: The FIND IN CONVEYOR command checks for film not only in the conveyer system, but in the entire machine. The result of the check is displayed as a status message in a separate dialog box. None STATUS: Value range: 0 - 14 0 = no film found; 1 - 14 = film found 1 - 7: film found at various locations in belt and loader system 9: only film at US1 10 - 11: film in drum - film not cut 12 - 14: film in drum - film is cut In case of error situation, eg. a film jam, the system does not display at status message but an error code.
Notes:
SPEC LOAD TST The SPEC LOAD TST command contains five sub-commands for loading a film and adjusting the position of a loaded film. LOAD NO US Operation: The LOAD NO US command loads the film without using the ultra sound sensors. Loading without the ultra sound sensors is not as accurate as loading with the ultra sound sensors. None PURUP PREPRESS A/S
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Output data: Notes:
None 1. The magazine must be in position. 2. The film snip must be pointing downwards (not resting behind the snip sensor). 3. Remove the film by SPECIAL + FILM P LACEMENT + FIND&EJECT FILM.
TEST MAG EMPTY Operation: Input data: Output data: Notes: The TEST MAG EMPTY command tests if the magazine in position is empty. None None The snip sensor and US sensor 1 are used during this test.
FILM AWAY US1 Operation: The FILM AWAY US1 command backs up the film past the ultra sound sensor no. 1. None None Depending on the film snip length, the film will finally disappear into the machine.
INIT BACK FILM Operation: The INIT BACK FILM command positions the film snip (the leading edge of the film) 20mm/0.75 inch above the ultrasound sensor no. 1. None None Use this function before a function test to make sure that there is no film in front of ultrasound sensor no. 1.
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ADJUST SNIPLGT Operation: The ADJUST SNIPLGT (film snip length) command positions the leading edge of the film exactly in front of ultrasound sensor no. 1. None None Reel off some film from the selected film roll (20-30 cm). Position the magazine/film roll. Select ADJUST SNIP LENGTH to check the snip sensor function). TBD
AWAY FILM
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2.1.2.5. Magazine
The MAGAZINE command contains a number of commands for controlling the film roll magazine.
MAG TO POS Operation: The MAG TO POS command positions a film roll magazine in load position. The number of the film roll magazine is specified in the dialogue box. MAGAZINE NO.: Value range: 1 - 3 None Can be used when servicing the magazine system or adjusting/replacing magazine hall elements.
FUNC TEST Operation: The FUNC TEST command makes a complete function test of the film roll magazine. The magazine function test also includes a test of ultrasound sensor 1. During the test the film is also backed up by the loading system etc. None None
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CHECK POS Operation: The CHECK POS command checks if one of the three film roll magazines are positioned correctly in load position. None None This command does not give any feedback. To see if the magazine is positioned correctly, use the "MAGAZINE IN USE" command. If the magazine is not positioned correctly, this is indicated by a "*". To position the magazine correctly, use the "FTEST DIRECT" command.
POS 1 Operation: The POS 1 command positions the film roll no. 1 in load position, but film is not loaded into the drum. Film roll no. 3 is now available for a film roll change. None None The actual change of film rolls must be carried out using the "Change Film Roll" command.
POS 2 Operation: The POS 2 command positions the film roll no. 2 in load position, but film is not loaded into the drum. Film roll no. 1 is now available for a film roll change. None None The actual change of film rolls must be carried out using the "Change Film Roll" command.
POS 3 Operation: The POS 3 command positions the film roll no. 3 in load position, but film is not PURUP PREPRESS A/S
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loaded into the drum. Film roll no. 2 is now available for a film roll change. None None The actual change of film rolls must be carried out using the "Change Film Roll" command. TBD TBD TBD
MOUNT ROLL 1 MOUNT ROLL 2 MOUNT ROLL 3
FTEST DIRECT Operation: Input data: The FTEST DIRECT command performs a function test of the magazine alone. COMMAND: Value range: 0; 7; 8 0 = Test all three magazines 7 = Test magazine in load position 8 = Test next magazine to be in load position None The FTEST DIRECT command does not make use of or test US1. Any film snips are not reeled back onto the roll. This test must always be used after replacing magazine, hall element, etc.
Output data: Notes:
TURN MAGAZINE Operation: The TURN MAGAZINE command turns the magazine as specified in the dialogue box. The direction and the speed of the turn are the same as used in normal operation. LENGTH: Value range: 10 - 1000 (2800 = one full SERVICE MANUAL
Input data:
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Output data: Notes:
revolution) None This function is a manual move/rotation of the magazine, and it is necessary to execute MAG TO POS after this command.
AUTOM. SWITCH ADJUSTMENT When you have keyed in the service password (11 times date) you will see the following:
Operation:
This function is used in connection with adjustment of the magazine (see 3.3.1.3). The operation takes approx. 10 minutes and optimizes SCM parameter 616. NONE New value for SCM 616 (if between 8 and 12: OK)
When you run the Automatic Switch Adjustment, the parameter value shown when the program is finished must be between 8 and 12 (SCM parameter 616 is automatically updated). When the test is finished, the last message shown is an error 1332 Parameter Adjust OK. Using the Show and Service commands you can display the Parameter OK data. This value must be minimum 5 to have a stable system. If this value is low (less than 5) or if you get an error 1331 Parameter adjust not certain, you should readjust the switch (see page 3.3.2 in the manual).
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2.1.2.6. Register
The REGISTER command contains a number of commands for controlling the punch registration system. The units can be tested individually.
UNITS UP Operation: The UNITS UP command pulls up the punch registration units. The film can now be unloaded. Register no. (1-14, 0= all) None None
Input data: Output data: Notes: UNITS DOWN Operation:
Input data: Output data: Notes: FUNC TEST Operation: Input data: Output data:
The UNITS DOWN command activates the punch registration units. The film is punched. Register no. (1-14, 0= all) None None
The FUNC TEST command performs a function test of the register system. Register no. (1-14, 0= all) None
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Notes: 2.1.2.7. Cutter
None
The CUTTER command contains a number of commands for controlling the cutting wheel.
CUT LENGTH Operation: The CUT LENGTH command moves the cutting wheel the distance specified in the dialogue box. LENGTH: Value range: 50 - 4000 Unit: 1/8mm/0.05 inch DIRECTION: Value range: 0; 1 0 = right 1 = left None Remember to do a Clean UP (FILM PLACEMENT + FIND AND EJECT FILM) in order to drive the cutter in home position.
Input data:
Output data: Notes:
CUT LEFT Operation: Input data: The CUT LEFT command positions the cutting wheel at the left end-stop. None
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Output data: Notes: CUT RIGHT Operation:
None None
Input data: Output data: Notes: FUNC TEST Operation: Input data:
The CUT RIGHT command positions the cutting wheel at the right endstop. None None None
Output data: Notes:
The FUNC TEST command performs a function test of the cutting system. DIRECTION: Value range: 0; 1 0 = right 1 = left None Use this test after servicing the cutting system.
CHECK POS Operation: The CHECK POS command checks the current position of the cutting wheel and sends this information back to the system. None The actual position. None
Input data: Output data: Notes: CUT SEQUENCE Operation:
The CUT SEQUENCE command cuts the film by moving the cutting wheel from its present position to the right end-stop and then back to the left endstop. None None Make sure that the film is tightened before you use this command. SERVICE MANUAL
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If the cutting wheel is positioned at the right end-stop, you will get an error message.
2.1.2.8. Focus
The FOCUS command contains a number of commands for controlling the focus adjustment.
POSITION Operation: The POSITION command moves the focus system to the position specified in the dialogue box. POSITION: Value range: 10000 25000 Zero position: 10000 None Always make a functional test of the focus system before driving the focus anywhere. If not, you are risking a mechanical collision in between the focus system and the rotating/ spinner optics!
Input data:
Output data: Notes:
DRIVE Operation: The DRIVE command makes the focus unit turn in the direction and distance
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Input data:
Output data: Warning:
specified in the dialogue box. DIRECTION: Value range: 0; 1 0 = right 1 = left LENGTH: Value range: 0 - 24000 None. Always make a functional test of the focus system before driving the focus anywhere. If not, you are risking a mechanical collision in between the focus system and the rotating/ spinner optics!
FUNC TEST Operation: The FUNC TEST command performs a function test of the focus system. The function test of the focus system takes approximately three minutes. None None Focus must be selected in the Configuration program. If not, focus will not return to zero position after the function test.
FOCUS FILM Operation: The Focus film command produces a focus film. The focus film is used to calibrate the exact focus position for the selected exposure medium (see chapter 2.5. Test Films) TBD TBD TBD
Input data: Output data: Notes: SET FOCUS Operation:
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Use the SET FOCUS command after completing a FOCUS FILM in order to position the focus lens in the optimal position Position of best focus: TBD SERVICE MANUAL
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Output data: Notes: ROT. TEST DRIVE W/SPEED
None
TBD TBD
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2.1.2.9. Iris
The IRIS command contains a number of commands for controlling the iris system.
POSITION Operation: The POSITION command places the iris system in the position specified in the dialogue box. POSITION: Value range: 4000 - 7800 None Always make a functional test of the IRIS system before doing this manual operation.
DRIVE Operation: The DRIVE command turns the iris motor in the direction and the distance specified in the dialogue box. DIRECTION: Value range: 0; 1 0 = close,1 = open LENGTH: Value range: 0 - 4500 None Always make a functional test of the IRIS system before doing this manual operation.
Input data:
Output data: Notes:
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FUNC TEST Operation: Input data: Output data: Notes: The FUNC TEST command performs a function test of the iris system. None None After the functional test, the IRIS is positioned in "0", corresponding to IRIS value = 4000
ROT TEST Operation: Input data: Output data: Notes: The ROT TEST command performs a test of the iris rotation detector. None None If the test is negative, an error code will be displayed.
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2.1.2.10. Carriage
The CARRIAGE command contains a number of commands for controlling the carriage system.
TO ZERO POINT Operation: The TO ZERO POINT commands moves the carriage to the zero point. This may take up to five minutes, depending on the current position of the carriage. None None Use this command to check if the system finds the zero point correctly.
MOVE LEFT Operation: The MOVE LEFT command moves the carriage left in express mode. The distance is specified in the dialog box. LENGTH: Value range: 0 - 820 Unit: mm None Make sure that the input data are valid.
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MOVE RIGHT Operation: The MOVE RIGHT command moves the carriage right in express mode. The distance is specified in the dialog box. LENGTH: Value range: 0 - 820 Unit: mm None Make sure that the input data are valid.
FUNC TEST Operation: The FUNC TEST command performs a complete function test of the carriage system. None None Use this function after servicing or when the carriage is in an unknown position. After a function test the carriage will be parked 2.5 mm from the reference point of the mechanical micro sensor.
START RAMP TEST Operation: Input data: Output data: Notes: STOP RAMP TEST Operation: Input data: Output data: Notes: Stops the ramp test None None None The ramp test performs a continuous ramp test of the carriage 200-9900 giving the distance of carriage travel. None The test is stopped by stop ramp test
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SPDM TEST Operation: Input data: Output data: The test runs though all setup possibilities. None Status can be read on the display on the SPDM module: 2nd display from the left 0" to F inclusive Hexadecimal 0" to F inclusive Hexadecimal 0" to F inclusive Hexadecimal 0" to F inclusive Hexadecimal
1st display d h F q
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2.1.2.11. Vacuum
The VACCUM command contains a number of commands for controlling the vacuum system.
VAC PUMP ON Operation: Input data: Output data: Notes: The VAC PUMP ON command starts the vacuum pump. None None The vaccum valve must be directed towards the manifold, or an error code will be generated.
VAC PUMP OFF Operation: Input data: Output data: Notes: VAC DIRECT ON VAC DIRECT OFF The VAC PUMP OFF command stops the vacuum pump. None None
TBD TBD
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VALVE F-TEST Operation: Input data: Output data: Notes: VALVE POSITION Operation: The VALVE POSITION command turns the vacuum valve to the position specified in the dialog box. VALVE POSITION: Value range: 0; 1; 2 0 = free air 1 = manifold 2 = waste container None The VALVE F-TEST command makes a function test of the vacuum valve. None None
Input data:
Output data: Notes:
CHECK VALVE POSITION Operation: The CHECK VALVE POSITION command checks the current position of the valve.
Input data: Output data: Notes: VACUUM SYSTEM TEST Operation: The VACUUM SYSTEM TEST command makes a function test of both the vacuum valve and the vacuum pump, starting with the vacuum valve. None None
MEASURE VACUUM TBD
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2.1.2.12. Processor
The PROCESSOR command contains a number of commands for testing the processor interface.
SET PROREQ Operation: The SET PROREQ command switches on the Processor Request signal to the on-line film processor. None None The interface program must be running.
REMOVE PROREQ Operation: The REMOVE PROREQ command switches off the Processor Request signal to the on-line film processor. None None The interface program must be running.
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GET READY STATUS Operation: The GET READY STATUS command sets the ImageMaker to await the Processor Ready signal from the processor. WAITTIME:Value range: 0 - 100 Unit: 0.5 second (defines how long the MAGNUM waits for the Processor Ready signal before giving an error message) None The interface program must be running.
Input data:
Output data: Notes:
PROCESSOR TALK Operation: Input data: With this command you can toggle the solenoid for alternative processor. 1 = Std (solenoid not active) 2 = Alternative processor (solnoide active) None The interface program must be running and the alternative processor enabled in the configuration.
Output data: Notes:
FILM PROC TEST Operation: This function allows you to perform a number of measurements and adjustments on the online film processor. For example, measuring the signal values and adjusting the trig levels (limits) for each signal. The ImageMaker PC receives six types of signals from the film processor. These signal are listed at the far left in the upper part of the dialog box. PROCON: PRORDY: PROFIN: PURUP PREPRESS A/S processor is switched on processor is ready processor is ready to SERVICE MANUAL
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receive film PROJAM: processor jam alarm PROTEMP: processor temperature alarm PROLEV: processor fluid level alarm Each of these signals can be selected by clicking in the small rectangle at the left of the name of the signal. A "X" in the rectangle indicates that the signal is switched on. To the right of each of the six signals you'll find six parameter fields. These parameter fields are used to adjust the individual signal. Last measured signal value Logic value using "LIMIT" as trig level the system standard trig level the currently used trig level the measured minimum value the measured maximum value
SIGNAL: LOGIC: DEFAULT: LIMIT: LOW: HIGH:
In the lower part of the dialog box you'll find seven commands which are activated by clicking the circle and clicking OK. These commands are: MEASURE measures the current signal value(s) SIGNAL: from the film processor. LOW LEVEL: stores the measured signal values as minimum values. HIGH LEVEL: stores the measured signal values as maximum values. NEW LIMIT: calculates a LIMIT value (= an average value based on the LOW and HIGH values) and replaces the old LIMIT value. MANUAL allows you to set the LIMIT value SETTING: manually . SET FILMPROCESSOR SERVICE MANUAL PURUP PREPRESS A/S
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REQUEST:
Activates a request signal to film processor. This will force PROFIN low. PROFIN will go high when request is removed and a film has entered the film processor.
REMOVE FILM- Removes the request signal. PROCESSOR REQUEST: All measurements and adjustments take place on the signal which are selected! Notes: Recommended LOW and HIGH values for a GLUNTZ and JENSEN PURUP PEZ000 Film Processor. LOW HIGH 50 2050 375 2080 130 220 150 260 150 260 150 260 Tolerance: +/- 5%
PROCON: PRORDY: PROFIN: PROJAM: PROTEMP: PROLEV:
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2.1.2.13. Laser
The LASER command contains a number of commands for controlling the laser adjustment. This applies for ImageMakers fitted with the Argon Ion laser as well as ImageMakers with the InfraRed laser diode.
LASER ON Operation: The LASER ON command switches on the laser beam. The command uses the power value which has been specified in the SET LASERPOWER dialog box. None None A power value must be specified in the SET LASERPOWER dialog box before you will see any laser light.
LASER OFF Operation: Input data: Output data: Notes: SET LASERPOWER The LASER OFF command switches off the laser beam. None None None
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Operation:
The SET LASERPOWER command sets the laser power. This applies both to Argon Ion laser as well as InfraRed laser diodes. POWER VALUE: Value range: 0 - 4095 None IR lasers should never be operated with a power value higher than 2500. If the laser diode constants are given and keyed in, the software will not allow you to exceed the maximum laser power.
SPINENC DIRECT ON Operation: The SPINENC DIRECT ON command connects the spindel encoder directly to the bitmap signal. None None Use the SPINENC DIRECT OFF command to quit this command. The SPINENC DIRECT ON command is used to test the quality of the spindle system or an exposed film/paper.
SPINENC DIRECT OFF Operation: The SPINENC DIRECT OFF command switches off the direct connection from the spindel encoder to the bitmap signal. None None
Input data: Output data: LASER FUNCTEST Operation: Input data: Output data:
The LASER FUNCTEST command None None
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LASER SHUTTER Operation: Input data: Output data: Notes: With this command you can toggle the laser shutter . 1= on, 0 = off. None None None
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2.1.2.14. Spinner
The SPINNER command contains a number of commands for controlling the spinner adjustment.
START SPINNER Operation: The START SPINNER command starts the spinner using the current spinner speed. None None None
Input data: Output data: Notes: STOP SPINNER Operation: Input data: Output data: None: SPEED 12000 Operation:
The STOP SPINNER command makes the spinner stop. None None None
The SPEED 12000 command sets the spinner speed at 12000 revolutions per minute. None None
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Notes: SPEED 24000 Operation:
None
Input data: Output data: Notes: MEASURE SPEED Operation:
The SPEED 24000 command sets the spinner speed at 24000 revolutions per minute. None None None
The MEASURE SPEED command measures the current speed of the spinner. None A new dialog box displays the spinner speed in revolutions per minute every time you press Enter or click OK. TBD
FUNC TEST :
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2.1.2.15. Security
The SECURITY command contains a number of commands for testing the ImageMaker security system. The security system is also referred to as the "24V system".
TEST SC4 TEST SC5 TEST SC6 TEST PGM
TBD TBD TBD TBD
TEST SECURITY SYSTEM Operation: The TEST SECURITY SYSTEM command displays the current status of the security system. None Yes = security system circuit is active No = security system circuit is NOT active ?= security system circuit status unknown Use this function to test hall elements on cabinet doors, and fast verification SERVICE MANUAL
Notes:
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of voltages a.o.
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PURUP IMAGEMAKER MAGNUM TROUBLESHOOTING
PAGE 2.2.1
2.2. Troubleshooting
2.2.1. PC Troubleshooting
Please consult the PC Operating Manual.
2.2.2. Purup ImageMaker MAGNUM Troubleshooting
This chapter gives a brief troubleshooting guide to the MAGNUM, and it is meant as a help to find out where to find an error on the MAGNUM, i.e. whether is a hardware or a software error and where to look for the error.
2.2.2.1. Errors During Initialisation 2.2.2.2. Errors During PC-Program Start If it is impossible to start the control program on the PC, the error is probably in the PC hard disk contents. Therefore, the software must be reinstalled, or the standard check procedure for the PC must be followed.
2.2.2.3. Errors During PC Control Program Initialisation
When the control program has been started, the various configuration files are read. If there are any missing files or files with scrambled contents, as e.g. after a hard disk crash, the error messages will be such as: Error in file... or Bad data in .... If this is the case, the software must be reinstalled.
2.2.2.4. Errors During Communication Check
After the initialisation the software checks the communication between PC and MAGNUM. If the communication does not work properly, the software will go into "BAD INIT ERROR" and there will be error messages such as "NO CONTACT TO ....". If there is an error message on the BITBUS MASTER, the
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MAGNUM should be switched off and on again. If there is no contact to any of the modules in the machine (PGM, SCM), the error may be caused by: 1. There is no voltage on the modules in the machine. This is the most frequent cause. The situation may occur, if e.g. the machine has been switched on when the service key is in service position. The power supply will then be disconnected. The error is corrected by switching off the machine on the main switch, waiting for 5 minutes and switching it on again. Error in the cable connections to the MAGNUM.
2.
A program called BBM can be used for testing the communication between the PC and the MAGNUM. This is described in the following section:
2.2.2.4.1. Use of BBM
This section describes briefly how to use BBM for trouble shooting on the communication between the PC and the MAGNUM, or rather between the PC and all of the internal MAGNUM modules. All commands must be ended by the return key, and inverted commas are not included. 1. Exit all control programs to DOS. There must be a prompt. Switch the PC off and on, or use CTRL-ALT-DEL. AUTOBOOT is interrupted by pressing a key. Exit the MAIN program to DOS. Enter the program directory by writing "CD C:\ELEF\PROGS". Write "BBM". Test whether the built-in master board in the PC is connected by writing "SYS FF". The result must PURUP PREPRESS A/S
2. 3. 4. 5.
6. 7.
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appear within 2 seconds and show some TASK ID's on the screen. 8. Repeat point 7 if the result is "PROTOCOL ERROR". If this is unsuccessful thrice, the master board in the PC has an error. If the master board is not connected, check whether the PGM module is connected. Write "SYS 1". The result must appear within 2 seconds. Repeat point 9 if the result is "PROTOCOL ERROR". If this is unsuccessful thrice, the communication has an error. Check whether any modules are connected. Test the BTM module by repeating point 9 and 10, however, with the command "SYS 3". Test the SC4 module by repeating point 9 and 10, however, with the command "SYS 4". Test the SC5 module by repeating point 9 and 10, however, with the command "SYS 5". Test the SC6 module by repeating point 9 and 10, however, with the command "SYS 6". Test the SC7 module by repeating point 9 and 10, however, with the command SYS 7".
9.
10.
11.
12.
13.
14.
15.
If no modules at all are connected the error is either in the cable from the PC to the MAGNUM, in the master board, or there is no voltage on the machines. If some of the modules are connected, the error is internally in the MAGNUM. When all of the MAGNUM modules have been connected, the BBM program is exited by writing "EXIT" and then the control programs are restarted by writing "RUNPIM".
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2.2.2.5. Errors During Purup ImageMaker MAGNUM Program Load
Programs are read from the PC hard disk and loaded via the bitbus net to the individual electronic modules in the MAGNUM. If there is an error during MAGNUM program load, the error message will indicate the cause. The most frequent error is lacking program files or program files with scrambled contents. If this is the case, the software must be reinstalled. Another error is bitbus protocol error during load. If this is the case, there is an error on the bitbus net, or a module interface part is bad. It can be checked by BBM as described in section 2.2.2.4.1.
2.2.2.6. Errors During Start of Purup ImageMaker MAGNUM Communication
When all programs have been loaded from the PC to the MAGNUM, the communication protocol is started. Errors during communication start are caused and corrected as described in chapter 2.2.2.4.
2.2.2.7. Errors During SW Version Check
If there are error messages during check of the hardware and software versions on the individual modules, it is caused by the installation. If there is a software version error, the program has not been installed correctly. You must then reinstall the software. If there is a hardware version error, you must replace modules with old versions. If the PS-Link is switched off, or if the optical fibre has not been connected, the version check on the BTM module will give an error message. Also, error 768 will occur and later various bitbus communication errors in the BTM module.
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2.2.2.8. Errors During Machine Voltage Check
When the communication has been started, the MAGNUM tests whether there is 24V voltage on the machine. The MAGNUM will indicate if there is no 24V voltage. This can be caused by: Open doors. Magnets on doors or hall elements are not placed correctly. Carriage is in emergency stop. Error on a safety loop. ON/OFF switch pressed twice (spontaneous powerdown) As a test the service key can be turned, and this will give the voltage if the carriage is not in emergency stop. However, the error must be corrected. If the MAGNUM continues without voltage, the following initialisation sequences will also cause errors. Load the Service program and select CONTROL + SECURITY to get a detailed overview.
2.2.2.9. Errors During Clean Up
Before a function test or a film exposure the MAGNUM will clean up, and set the machine in zero position. If an error occurs during this clean up, error messages indicate the cause, and "PIM CLEANUP FAILED" will occur on the screen. The user can now let the MAGNUM retry the clean up or abort and continue. It is important that you do not let the MAGNUM continue a function test if the clean up has failed. The cause of the error must be found and corrected. The error could be a piece of jammed film in the machine. Always try to eliminate the error, and repeat clean up. If you let the MAGNUM continue, and there is a piece of jammed film in the machine, the function test will also fail, and the machine will not be able to expose films until there has been a faultless function test on all systems.
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2.2.2.10. Errors During Function Test
During initialisation the MAGNUM runs a function test on all systems. The described procedure for troubleshooting can only be used on a machine that has completed an installation test. A MAGNUM that fails during a function test will not be able to expose films. If the function test fails on a system, the function test stops, and the MAGNUM will give an error message indicating the cause. The user can now either repeat the function test on the rest of the systems, or abort and continue. You should always try to repeat the function test at least once, if you do not succeed, abort and enter the service program. Here you can test the faulty system. The test on the faulty system must be completed before you can expose films. The error message given when you run a manual function test on the faulty system indicates the cause of the error. In a few cases errors during a function test are caused by destroyed parameters. If the parameters are destroyed, exit to the MAIN program, enter the configuration program, choose restore of parameters, exit, and restart the program.
2.2.2.11. Errors During Exposure
See chapter 2.6, Error Code List for evaluation of error codes.
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2.2.4. Production Startup
Production startup of a machine consists of different steps. For production startup only the basic config. diskette is used. Production startup consists of the following steps: 1. 2. 3. 4. 5. Setting the MAGNUM to zero position. Run part of the installation. Configure the MAGNUM correctly. Run an installation test. (Perhaps also program installation). Configure the different MAGNUM adjustments.
The individual steps are described in the following chapters.
2.2.4.1. Setting Purup ImageMaker MAGNUM to Zero Position
As the parameters are not machine specific, the MAGNUM cannot move to zero position. Therefore, it must be done manually.
2.2.4.2. Carriage
Move the carriage manually by turning the viscous damper to a position in the left side where the magnet on the carriage is placed exactly over the left hall element or slightly to the left. The carriage must not be in emergency stop.
2.2.4.3. Cutting Wheel
The cutting wheel must be placed in the left side at the end stop hall element.
2.2.4.4. Magazine
If a piece of film hangs out of the magazine in load position, roll it into the magazine by turning the rollers manually.
2.2.4.5. Installation of Software
When software is installed on a totally "raw" machine, you must interrupt the installation program before it runs an installation test. Start the installation program as described in the installation guide.
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When the files have been copied the installation program suggests that you run an initial function test. This test should not be run. Instead you interrupt the installation program by choosing QUIT until the normal main menu occurs. This is necessary to be able to configure the MAGNUM before the test is run as the "raw" config diskette contains a general configuration that does not fit to a specific machine.
2.2.4.6. Preconfiguration of Purup ImageMaker MAGNUM
Before the installation test is run on the MAGNUM, you must configure it so that the program knows how the MAGNUM is equipped. Choose "4. Configuration" in the main program, and setup the configuration as described in the following chapters. Below is a brief check list of what to configure before an installation test. 1. 2. 3. 4. 5. MAGNUM equipment in "MACHINE CONFIGURATION". Active electronic modules. Register system. Number of R/S lines. Spinner speed.
See item 2.3 Machine Configuration for further information
2.2.4.7. Initial Functest
In the main program you choose "7. Run installation test". The MAGNUM will then start up and run a total function test. The function test must be run without errors on any parts before you can continue. The difference between this way to start and a normal function test is: 1. 2. 3. The "original".RF1 parameter files are used automatically. The MAGNUM will not perform a CLEAN UP during start-up. When the test has been completed, the installation
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program will started again. If there are any errors during this function test, you must correct the error and repeat the function test. This possibility will appear automatically in case of an error. When the total function test has been completed without any errors, the control program is exited and the installation program restarted. A "good" machine-dependent parameter set has now been generated, and a backup will be saved in the .REF parameter files. You can now restart the machine as usual.
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PURUP IMAGEMAKER MAGNUM MACHINE CONFIGURATION
PAGE 2.3.1
2.3. Machine Configuration 2.3.1. Configuration in General The Purup ImageMaker MAGNUM configuration is enclosed in the configuration diskette supplied by Purup Prepress. The MAGNUM configuration consists of various parts briefly described in the following sections. The Configuration program holds information on how each individual MAGNUM is configured and adjusted: is the ImageMaker mounted with an Argon Ion laser or an infrared laser diode? is the ImageMaker equipped with the optional Climate control?
Besides information on configuration, the Configuration program also contains film definition files with information on density settings and parameter information files. Note Because the configuration values are set individually for each MAGNUM, the setup values in this manual are only typical examples and may not be valid for the MAGNUM which you are servicing.
Whenever you change one or more of the parameters in the Configuration program, a message at the bottom of the screen will ask you to update the backup copy on your Config diskette. Make sure that you always update the Config diskette after changing the configuration.
2.3.1.1. Using the Configuration Program
To branch to the Configuration program, follow these steps: 1. Choose the "Main program" command in the Exit menu.
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2.
Select "4. Configuration" in the Main program menu.
The "Configuration Main menu" screen image appears.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ---------------------------------------------------------------------------------------CONFIGURATION MAIN MENU --------------------------------------------A. Exit program B. Define film types C. Runtime information D. Define register types E. Define active modules F. Setup machine configuration G. Define machine constants H. Restore and Back up -------------------------------------------------------------------------------------------
In the following sections, each of the eight commands are explained. These commands are not explained in detail.
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Exit program The "Exit program" command closes the Configuration program and returns you to the Main program menu.
2.3.1.2. Define Film Types
The "Define film types" command is parallel to the "Define Film Type" command in the User program except for the graphic user interface. We recommend that you use the "Define film types" command in the User program. See also the User's Manual for further information. The film data menu is shown below:
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 CHANGE FILM DATA Film no. Date (mm/dd/yy) Film name 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 07/31/95 07/31/95 07/31/95 Film not defined Film not defined Film not defined Film not defined Film not defined Film not defined Film not defined Kodak ESY (0.11mm) Kodak SAI7 (0.20mm) Kodak ESY (0.10mm/Brake)
Save current film definition Delete film definition Copy film definition
------------------------------------------------------------------------------------------> Enter the film number to change, 0 to exit:
If you enter film number 1 you will get the following:
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PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.02 CHANGE FILM DATA FOR FILM NO. 1 Date (mm/dd/yy) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Film name Focus Iris 20 Iris 10 Iris 8 Iris 6.4 Iris 5 Film thickness in m Load length dev. (1000=none) Handling speed (0-2) Film proc. (0=def,1=opt) Power/density ARFilm 21067 6300 5500 5000 4400 3600 100 1000 0 1 IRFilm 21067 5500 5050 4400 07/09/96 HeNeFilm 21067 6100 5000 4300 3600 100 1000 0 1
100 1000 0 1
------------------------------------------------------------------------------------------------> Select parameter to change or 0 to exit :
1.
Film name:
This name is normally keyed in from the user menu Define film type. This figure indicates the focus position. This value is normally keyed in from the service menu Set focus. These values indicate the Iris position fo the individual resolutions. Note that the different light sources have different values. For later use. This value indicates the load characteristic of the medium. The value 1000 means no compensation. Please refer to chapter 2.8 for futher information. Used for adjustment of the load speed
2.
Focus:
3,4,5,6,7. Iris:
8. 9.
Film thickness: Load length dev:
10. Handling speed:
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0 = Reduced speed, 1 = normal speed, 2 = high speed. 11. Film proc.: Used for systems with dual output, e.g. when both film and polyester plates are used simultaneously. Position 1 activates solenoids in the processor for alternative processor. For the next film with 0 default processor, the solenoids are deactivated. Produces a screen image showing the power/density values set from the user menu.
12. Power/density:
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2.3.1.3. Runtime Information
The "Runtime Information" command is identical with the "Runtime Information command in the Main program except for the graphic user interface. We recommend that you use the "Statistical features" command in the Main program. See also the User's Manual for further information. Note: The start-up will fail if the Runtime Info is all 0, and error 524 will be displayed. This usually happens if the MAGNUM has been powered off illegally. Correct the error by entering the estimated data in the Runtime Info menu.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 CHANGE RUNTIME INFORMATION No. Descr. 1. 2. 3. 4. Total run time (hours) Carriage run length (m) Spinner run time at 12000 rpm (hours) Spinner run time at 24000 rpm (hours) Value 87 213 53 34
8. 9.
Password Save current run time information
------------------------------------------------------------------------------------------------> Enter menu number or 0 to exit:
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2.3.1.4. Define Register Types
The Magnum can hold up to 14 registers, controlled by SCM 4, SCM 5, and SCM 7 (optional), and the cofiguration has to be correct in order for the system to work in the correct way. The procedure below is a guide to define a register system, and it can be used no matter whether it is a Head, Tail or Side register system.
Side
Head Exposure Area (1200 * 820)
Tail
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2.3.1.4.1. Configuration of the Register System
1)
Select D-Define Registers from the Configuration menu, and the following menu will appear:
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.02 960531 ______________________________________________________ CHANGE REGISTER TYPES ______________________________________________________ Unit no. Reg.no. Reg.name Offset(m) 2 3 4 5 6 10 1. 2. 3. 4. 5. 6. 7. 8. 9. Heidelberg Speed 102 Reg.type not defined. Reg.type not defined. Reg.type not defined. Reg.type not defined. Reg.type not defined. Reg.type not defined. Reg.type not defined. Reg.type not defined. 0 0 0 0 0 0 0 0 0 +++++
10. Change physical register configuration. 11. Delete register type. 12. Save current register types. ______________________________________________________ --> Enter the reg.type no. to change, 0 to exit :
Note: offset (m) must be 0!
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2)
Define the amount of register units, mounted in the machine, by selecting menu item 10 Change Physical Register Configuration. The following menu will appear:
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.02 960531 ______________________________________________________ CHANGE PHYSICAL REGISTER CONFIGURATION ______________________________________________________ Unit Conf. Node Length (X) Width(Y) x1 y1 x2 y2 1 2.1 3.1 4.1 5.1 6.1 7. 8. 9. 10.1 10.2 11. 12.
+ + + + +
4 4 4 5 5
140500 318000 514500 711000 888500
8000 8000 8000 8000 8000
-16 -16 -16 -16 -16
-8 -8 -8 -8 -8
16 16 16 16 16
8 8 8 8 8
0 999999
0 8000
0 -22
0 0 -12 22
0 12
15 Setup default register shadow shapes ______________________________________________________ --> Enter Unit number (or PgUp/PgDown) or 0 to exit:
3)
If mounted, verify the physical presence of register unit 1, by entering 1. Enter 1 to add unit no. 1. Enter position number. Position 1 is used if this is a normal register unit with one hole. If it is a double unit, position 2 is used. Unit 10 is an example of such a unit. Enter 1 to change position. Key in position and then shadow values. Note: The values keyed in for register unit position are unscaled. You can therefore not measure the register unit position on the evaluation film and key in the values
4) 5)
6)
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unless the scaling factor is 1:1. The register unit positions indicated in SPT are the scaled figures, and not the unscaled that you keyed in. 7) Enter all data for the individual register unit, as described below: UNIT => The selected wiring set for the register unit. CONF => The register wiring set is active. (+) NODE => Displaying which SCM (4-5-7) controlling the register wiring set (info only). X () => From Horisontal Start of Scan (HSOS) to register pin center. Y () => From Vertical Start of Scan (VSOS) to register pin center. X1(mm) => Distance from start of shadow to register pin center (neg. val.) Y1(mm) => Distance from start of shadow to register pin center (neg. val.) X2(mm) => Distance from end of shadow to register pin center (pos. val.) Y2(mm) => Distance from end of shadow to register pin center (pos. val.) The X1, Y1 and X2, Y2 values depend very much on what kind of register unit is mounted in the individual positions. Determine the X1 and X2 values by measuring the register shadow, for the individual register unit, and devide by 2, resulting in a value to be entered as negative (X1) and positive (X2), with register pin center as reference.
Note :
ex.
Single Bacher register system, fitting a Heidelberg Speedmaster 102.
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The Register Configuration Sceme would look as the one below: Punch Unit Type Distance to 0 Shadow X1/Y1 Shadow X2/Y2 Size mm Orientation Distance (unit/unit) 1 Secondary 140500 -16/-8 16/8 9.52/6.35 X 177.5mm 2 Secondary 318000 -16/-8 16/8 9.52/6.35 X 196.5mm 3 Reference 514500 -16/-8 16/8 9.52/6.35 Y 196.5mm 4 Secondary 711000 -16/-8 16/8 9.52/6.35 X 177.5mm 5 Secondary 888500 -16/-8 16/8 9.52/6.35 X -
8)
Remember to save the register info before leaving the configuration program.
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9)
Start the SERVICE PROGRAM and ignore any Clean Up errors. Perform a function test of the register system, and notice that all registers are active. Run test jobs from StandardPageTool, note the register shadow figures, and verify on other test jobs that all the distances are correct.
10)
11)
2.3.1.5. Define Active Modules
Choose "E.Define active modules" in the configuration program. A menu appears that enables you to connect and disconnect the individual electronic modules. All modules must be configured active (+), except for SCM7. SCM7 is only used if the MAGNUM is equipped with more than 7 register units.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 950915 CHANGE MODULE CONFIGURATION No 1. 2. 3. 4. 5. 6. Conf. + + + + + Module Pixel Generator module BITBUS-TAXI module Scanner Control module 4 Scanner Control module 5 Scanner Control module 6 Scanner Control module 7 (PGM) (BTM) (SC4) (SC5) (SC6) (SC7)
10.
Save current module configuration.
--------------------------------------------------------------------> Enter the menu number or 0 to exit:
Note :
The MAGNUM software can be run on a Stand Alone PC, for diagnostic purposes, without any of the modules being active. Furthermore, it is not necessary to have the BitBus Master Board mounted in the PC. PURUP PREPRESS A/S
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This setup can be used for telephone support to customers, if you need to observe closely the actions taken by the customer.
2.3.1.6. Setup Machine Configuration
The "Setup machine configuration" command holds information on the actual configuration of your MAGNUM. The Configuration setup is divided into five sub-menus which cover a specific area. The sub-menus are: 1. 2. 3. 4. 5. 6. Machine functions PS-Link Optional machine functions Version dependent machine functions Modem setup Film processing unit
The sub-menus are explained in chapter 2.3.2. Note: A number of Configuration values can be set both from the User program and the Configuration program. In the following overview these configuration values are marked with an *. It does not matter if the configuration values are set from the User program or the Configuration program. Because the configuration values are set individually for each MAGNUM, the setup values in this manual are only typical examples and may not be valid for the MAGNUM which you are servicing.
Note:
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2.3.1.7. Define Machine Constants
The "Define Machine Constants" command holds information on the machine dependent constants of the MAGNUM. Follow the procedure below in order to change the machine constants. 1) Select G-Define Machine Constants in the Configuration Main Menu, and the following menu will appear:
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 950915 -------------------------------------------------------------CHANGE MACHINE CONSTANTS ----------------------------------------------------------No. 1. 2. 3. 4. 5. 9. Descr. Change spinner constants Change carriage constants Change run/stop characteristics Change loader constants Change misc. constants Save current machine constants
---------------------------------------------------------------> Enter the menu number or 0 to exit:
2)
Enter the number of the sub-menu you want to modify, and press enter. How to set up or change the configuration is described in detail later in this chapter. Always remember to save the changes when you have altered the configuration setup. Because the Machine Constants are configured for each individual MAGNUM, the machine constants in this manual are only typical examples and may not be valid for the MAGNUM that you are servicing.
Note :
3)
Select 9-Save current machine constants to store the new setup.
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Note :
When you have saved the new setup, you will automatically return to the Configuraton Main Menu.
4)
Select A-Exit program to return to the Main Program menu. A message at the bottom of the screen will ask you to make a back-up copy of the machine configuration setup on the Config diskette. This message only appears if you have changed configuration values.
Note :
5)
Enter 1, insert the Config Diskette, and press the ENTER key.
When the back-up procedure is completed, you will return to the Main Menu
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2.3.2. Changing the Configuration Setup
Follow these steps: 1. Select "F. Setup Machine Configuration" in the Configuration Main menu. The "Setup Machine Configuration" screen image appears.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE MACHINE CONFIGURATION --------------------------No. 1. 2. 3. 4. 5. 6. Descr. Machine functions PS-Link Optional machine functions Version dependent machine functions Modem setup Film processing unit
9.
Save current machine configuration
--------------------------------------------------------> Enter the menu number or 0 to exit:
2.
Enter the number of the sub-menu you want. How to set up configuration values in each of the five sub-menus is described in detail later in this chapter. Note Always remember to save the changes, when you have changed the configuration setup.
3.
Select "9. Save current machine configuration" to store the new configuration setup. When you have saved the changes, you will return to the Configuration main menu.
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4.
Select "A. Exit program" to return to the Main program menu. A message at the bottom of the screen will ask you to make a backup copy of the machine configuration setup on the Config diskette. This message only appears if you have changed and saved configuration values.
5. 6.
Enter "1" and insert the Config diskette. Press the ENTER key to start the backup process. When the backup is completed, you will return to the Main program menu automatically.
2.3.2.1. Machine Functions
This group of configuration values controls the basic units and functions of the MAGNUM. The basic units and functions are the units and functions that are found on all ImageMaker models, regardless of model number and software version number.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE MACHINE FUNCTIONS --------------------------------------------No. Conf. Unit 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. + + + + + + + + + + Film roll magazine Loader system Cutting system Vacuum pump Iris system Carriage Ultra sound film sensors Ultra sound film sensors in conveyor Vacuum distributor valve Film snip sensor
-----------------------------------------------------------> Enter the menu number or 0 to exit:
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Note 1. 2. 3.
+ = ON
- = OFF
Enter the number of the option you want to change. Enter "1" to turn on the option or "0" to turn it off. Enter "0" to exit. You will now return to the "Setup Machine Configuration" menu.
Overview of Machine Function Configuration Values 1. Film roll magazine: Position: Loader system: Position: 3. Cutting system: Position: Vacuum pump: Position: Iris system: Position: 6. Carriage: Position: Ultra sound film sensors: Position: Ultra sound film sensors in conveyor Position: Vacuum distributor valve: Position: controls the film magazine. should always be + (ON). controls the feeding of film into the drum. should always be + (ON). controls the cutting of film. should always be + (ON). controls the vacuum pump. should always be + (ON). controls the aperture in the exposure optics. should always be + (ON). controls the carriage. should always be + (ON). controls the position of film in the ImageMaker. should always be + (ON). controls the jam sensors in the conveyor. should always be + (ON). controls the vacuum valve. should always be + (ON). PURUP PREPRESS A/S
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4.
5.
7.
8.
9.
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10.
Film snip sensor:
Position:
controls if the leading edge of the film roll is positioned correctly. should always be + (ON).
2.3.2.2. PS-Link RIP Communication Setup
This group of configuration values controls the communication of data between the PS-Link RIP and the ImageMaker.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE PS-LINK CONFIGURATION ------------------------------------------------No. Conf. Unit 1. 2. 3. 4. 5. 6. 7. 8. + + + + + + + PS-Link connected Simultaneous transmission of film roll data Alarm messages transmitted to PS-Link Status messages transmitted to PS-Link Extended PS-Link protocol type II Film roll empty error set PIM offline PS-Link Level 2 protocol type III RIP Offline after startup
------------------------------------------------------Enter the menu number or 0 to exit:
Note 1. 2. 3.
+ = ON
- = OFF
Enter the number of the option you want to change. Enter "1" to turn on the option or "0" to turn it off. Enter "0" to exit. You will now return to the "Setup Machine Configuration" screen image.
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Overview of PS-Link RIP Communication Setup 1. PS-Link connected: Position: 2. Simultaneous: transmission Position: controls the communication to the PS-Link RIP. should always be + (ON). controls instant feedback to the RIP of changes in film roll data. should always be + (ON) when connected to a Purup PS-Link RIP. controls if error messages are transmitted to the PS-Link RIP. should always be + (ON). controls if status messages are transmitted to the PS-Link RIP. should always be + (ON). controls the communication protocol to the PS-Link RIP. should always be + (ON) for PS-Link.
3.
Alarm messages:
Position: 4. Status messages:
Position: 5. Extended PS-Link RIP: protocol Type II Position:
6.
* PIM offline when film roll empty:
Position + (ON):
Position - (OFF):
stops all exposure when a film roll runs empty or skips all jobs for the empty film roll. select "+" when you want to stop exposure of all jobs until a new film roll is mounted. select "-" when you want the ImageMaker to skip all jobs for an empty film roll. controls the communication protocol to the PS-Link RIP. should always be + (ON) for PS-Link.
7.
PS-Link level 2 protocol Type III Position:
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8.
RIP offline after PIM startup
set "ON" (+) if the queued job must wait. set "OFF" (-) if the queued jobs must start.
2.3.2.3. Optional Machine Functions
This group of configuration values controls the optional functions and units on the MAGNUM such as the punch registration system, climate control system and others.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.02 960531 -------------------------------------------------------------CHANGE MACHINE CONFIGURATION ------------------------------------------------------No. Conf. Unit 1. + Register punch system 2. Focus system 3. + Air conditioning unit 4. Infra red laser diode 5. Visible red laser diode 6. + Auto clean up function 7. Extended film roll selection 8. Power button passive 9. + Screen saver off 10. Offline sound 11. + Filter watch 12. Laser shutter function 13. Warnings off 14. Loader debug ----------------------------------------------------------------> Enter the menu number or 0 to exit:
Note 1. 2. 3.
+ = ON
- = OFF
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Overview of Optional Machine Function Configuration Values 1. Register system: Position: 2. Focus: Position: 3. Air conditioning unit: controls the punch registration system. should always be - (OFF) controls the focus adjustment. should always be - (OFF). specifies if the optional Climate control is installed in the ImageMaker. should be + (ON) if Climate control unit is installed; should be - (OFF) if a Climate control unit is not installed. specifies the laser type. should be + (ON) if the ImageMaker is equipped with a laser diode; should be - (OFF) if the ImageMaker is equipped with an argon-ion laser.
Position:
4.
Infrared Laser diode: Position:
5.
Visible red laser diode: Position:
specifies the laser type. should be + (ON) if the ImageMaker is equipped with a visible red diode / or the He-Ne laser system; should be - (off) if the ImageMaker is equipped with either an IR diode or AR laser. checks for film in the machine during start or after an error. should always be + (ON).
6.
Auto clean up:
Position:
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7.
* Extended film roll:
Position + (ON):
Position - (OFF):
controls the automatic selection of film magazines film magazines when a film roll runs empty. select "+" to make the MAGNUM select another film roll automatically. select "-" to make the MAGNUM stop all exposure or reject all jobs for the empty film roll, dependent on your selection in "ImageMaker offline when film roll empty". disables the power button's shut-down function to prevent the ImageMaker from being shut down by accident. select "+" to disable the power button's shutdown function. select "-" to switch on the power button's shutdown function.
8.
Power button passive:
Position + (ON):
Position - (OFF):
9.
* Screen saver off: Position + (ON): Position - (OFF):
switches on and off the screen saver function. select "+" to switch off the screen saver function. select "-" to switch on the screen saver function. makes the ImageMaker PC beep when the communication to the PSLink RIP is interrupted while the screen saver is active. select "+" to switch on the offline sound. select "-" to switch off the offline sound. SERVICE MANUAL
10.
* Offline sound:
Position + (ON): Position - (OFF):
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11.
Filter watch:
activates the dust filter sensor in Climate Control unit. The sensor sends a warning if the dust filter is clogged and needs to be replaced. select "+" to switch on the dust filter sensor. select "-" to switch off dust filter sensor. shuts the laser beam off during exposure, when waiting for data from RIP enables shutter disables shutter Only for HRL Lasers, type II suppresses all warnings that do not require any specific action. select "+" to suppress warnings. select "-" to allow all warnings to be displayed. We recommend that you use option + (ON) in suppress warnings during normal production. used for trouble-shooting on the loader system. Debug is on Debug is off
12.
Laser shutter:
Position +(ON) Position -(OFF) Note: 13. Warnings off:
14.
Loader debug: Position +(ON): Position -(OFF):
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2.3.2.4. Version Dependent Machine Functions
This group of configuration values controls the functions and units which are found only on specific models and versions of the ImageMaker.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.02 960531 ------------------------------------------------------CHANGE MACHINE CONFIGURATION ----------------------------------------------No. Conf. Unit 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. + + + + + + + + Sensor for film cut Film jam sensors on film guide in drum Laser fuse surveillance Air conditioning fuse surveillance Temperature sensors Film stop sensor in drum Carriage fast-mode motordriver Carriage hall-encoder No encoders on loader Vacuum valve motor driver B Carriage SPDM module
----------------------------------------------------------> Enter the menu number or 0 to exit:
Note 1. 2. 3.
+ = ON
- = OFF
Overview of Version Dependent Machine Functions 1. Sensor for film cut: Position: Film jam sensors on: controls the cutter. should normally be + (ON). controls the jam sensors in the film guide in drum SERVICE MANUAL
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Position: 3. Laser fuse: surveilance Position: Air conditioning: fuse surveillance Position: Temperature: sensors Position:
should normally be - (OFF). controls the laser fuse. should normally be + (ON). controls the air conditioning fuse. should normally be + (ON). controls the temperature sensors. should be + (ON) if the machine is equipped with temperature sensors.
4.
5.
6.
Film stop sensor in drum: Position:
Controls film load when loading maximum length
7.
Carriage motor fast mode: Position:
Controls the type of stepper motor driver (36V - 24V) + (ON) if 36V type (Magnum serial number >68, part no. 5803356); (OFF) if 24V type (Magnum serial number <68, part no. 5601525). Controls the Carriage hallencoder on the spindle assembly. + (ON) if hall element is present; - (OFF) if hall element is not present. Controls the encoders on the loader motors (roller/belt motor). + (ON) sets the loader encoders off for more accurate loading (newer motors do not have encoders, and therefore PURUP PREPRESS A/S
8.
Carriage hall-encoder:
Position:
9.
No encoders on loader:
Position:
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the ON position is mandatory when running with these motors. - (OFF) sets the encoders on and activates the encoder signal. 10. Vacuum valve motor driver B:
Position:
Controls the vacuum valve driver. New cabling connections are to be made on the SCM 6 connector board to change driver type (see technical note). The driver type can be changed from motor driver type C2 (weak) to the stronger type B. + (ON) selects the strong driver B (new cabling is to be made), - (OFF) normal position (driver C2) with original cabling.
11.
Carriage SPDM module:
Positions:
Controls if the SPDM module is present. The SPDM module makes it possible to SWcontrol current limiter in the spindle driver for better screen quality in high resolutions. Note that two power limiters on the driver are set to zero on the hex switch. + (ON) sets the SPDM module on, and a new menu appears in carriage constants, - (OFF) is selected when the SPDM module is not mounted.
2.3.2.5. Modem Configuration
This group of configuration values controls the basic setup of a modem installed on the ImageMaker Control PC. TBD
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2.3.2.6. Film Processing Unit
This group of configuration values controls the basic setup of the film processing unit connected to the MAGNUM.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE MACHINE CONFIGURATION --------------------------------------------No. Conf. Unit 1. 2. 3. 4. 5. Film processor Online conveyor jam from film processor Wait if film processor warning Wait if film processor is not ready Alternative film processor option.
------------------------------------------------------------> Enter the menu number or 0 to exit:
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2.3.3. Change Machine Constants
Follow these steps: 1. Select "G. Define Machine Constants" in the Configuration Main menu. The "Define Machine Constants" screen image appears.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM ------------------------------------------------------CHANGE MACHINE CONSTANTS ------------------------------------------------------No. 1. 2. 3. 4. 5 Descr. Change spinner constants Change carriage constants. Change RUN/STOP characteristics. Change loader constants. Change misc. constants
9.
Save current machine constants
2.
Enter the number of the sub-menu you want. How to set up machine constants in each of the six submenus is described in detail later in this chapter. Note Always remember to save the changes, when you have changed the machine constants.
3.
Select "9. Save current machine constants" to store the new configuration setup. When you have saved the changes, you will return to the Configuration main menu.
4.
Select "A. Exit program" to return to the Main program menu.
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A message at the bottom of the screen will ask you to make a backup copy of the machine constants on the Config diskette. This message only appears if you have changed and saved machine constants. 5. 6. Enter "1" and insert the Config diskette. Press the ENTER key to start the backup process. When the backup is completed, you will return to the Main program menu automatically.
2.3.3.1. Change Spinner Constants
1.
Select option "1. Change Spinner Constants" in the "G. Change Machine Constants", and the sub-menu below will appear on the screen of the PC.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE SPINNER DATA. ---------------------------------------------------No. Descr. 1. 2. 3. 4. 5. 6. Offset counter 5/10/20my Offset counter 6.4my Offset counter 8my Spinner speed (rpm) Spinner shut down time (sec.) Automatic offset setup Value 60800 76173 87153 24000 1000
Menu item 1 describes the Start of Scan (SOS) position inside the drum on the x-axis orientation (around drum). Please refer to chapter 2.8. Adjustments for further information. Note: When the offset for 5/10/20 m is set use point 6 (Automatic offset) in order to calculate offset for PURUP PREPRESS A/S
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8.4/6.4 m. This means that point 2 and 3 should not be changed. Menu item 4 describes the speed of the spinner inside the MAGNUM. Follow the procedure below to change the speed: 1. Select "1. Change Spinner Constants" in the menu "G. Change Machine Constants". Select point 4 and enter the required speed. Note: 24000 rpm is default. Here you state how many seconds after the last job on the Imagemaker the spinner should stay at the normal speed, and then decrease to idle speed to save wear of the spinner.
2.
3.
Select "5. Spinner Shut Down Time", and enter the desired number of seconds.
Remember to save/update the Config. diskette after the changes.
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2.3.3.2. Change Carriage Constants
Select option "2. Change Carriage Constants" in the menu "G. Change Machine Constants", and the sub-menu below will appear on the screen of the PC.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE CARRIAGE DATA. ------------------------------------------------------No. 1. 2. 3. 4. 5. Descr. Left end point in m. Right end point in 0.1 mm Single step delay: Maximum carriage speed in Khz: Carriage SPDM setup Value 6000 8300 3 4 60 45
1.
Menu item 1 describes the left end point of the carriage, also called the vertical SOS (Start of Scan). The left end point is normally used for adjusting the distance from the register system to the image start. The left end point (LEP) is always entered in 1/1000 mm (), and it is default set to 6000. The minimum LEP to be entered is 0.
2.
Menu item 2 describes the Right End Point (REP) of the carriage, also called the vertical EOS (End of Scan). The REP is always entered in 1/10 mm, and it is always dependent of the size of the LEP. See also the chapter on adjustment.
3.
Menu item 3 describes the delay between steps on the carriage motor. Values range from 0 to 10, and default value for machines with 24V stepper motor driver
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(Magnum serial number < 68, part no 5601525) is 3. For 36V driver (Magnum serial number > 68, part no 5803356) the default value is 4. If the carriage stops during function test or zero point search, the value can be increased with 2 until the carriage drives ok. On the new drivers (5803356) the motor current can be increased on the hex-switch if the change of delay does not help (the normal setting for fast step is C and it can be adjusted to D E or F). (On Mercury 9 and adjustment to A, B, C...) Note: On drivers with SPDM the hex switch is set to 0. 4. Menu item 4 decribes the maximum speed i kHz. On the 24V driver (magnum serial number < 68) the default value was set to 80, but often decreased to eg. 60 due to overload (carriage stops in reconance). On the 36V driver (Magnum sn > 68) the default setting is 45. Menu item 5 is only present when SPDM is activated in Change Machine Configuration, menu item 11. In the Carriage SPDM setup you can key in the current limiter for the carriage. There are 12 different values, Fast move, Search mode and exposure in all five resolutions and in both spinner directions.
5.
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PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.03 10/30/96 ------------------------------------------------------CARRIAGE SPDM SETUP ------------------------------------------------------No. Descr. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Current limit at 12000 20 my Current limit at 12000 10 my Current limit at 12000 8 my Current limit at 12000 6.4 my Current limit at 12000 5 my Current limit at 24000 20 my Current limit at 24000 10 my Current limit at 24000 8 my Current limit at 24000 6.4 my Current limit at 24000 5 my Current limit at Fast move Current limit at Search mode Magnum Mercur
3 2 2 10 7
2 2 1 7 4
12 15
12 15
Note: The values are shown as hex in the SPDM display. The given values are the known minimum values and can be increased if there are problems (e.g. the carriage stops). However, low values give better screen quality.
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2.3.3.3. Change RUN/STOP Characteristics
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE RUN/STOP ------------------------------------------------------No. 1. 2. 3. Descr. RS-lines Wait-lines No. of RS before shut laser Value
These settings are factory adjusted and should not be changed.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE RS-LINES ------------------------------------------------------No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Descr. RS-lines at 12000 20 my RS-lines at 12000 10 my RS-lines at 12000 8 my RS-lines at 12000 6.4 my RS-lines at 12000 5 my RS-lines at 24000 20 my RS-lines at 24000 10 my RS-lines at 24000 8 my RS-lines at 24000 6.4 my RS-lines at 24000 5 my Value 143 143 143 143 143 143 143 143 143 143
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PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE WAIT-LINES ------------------------------------------------------No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Descr. Wait-lines at 12000 20 my Wait-lines at 12000 10 my Wait-lines at 12000 8 my Wait-lines at 12000 6.4 my Wait-lines at 12000 5 my Wait-lines at 24000 20 my Wait-lines at 24000 10 my Wait-lines at 24000 8 my Wait-lines at 24000 6.4 my Wait-lines at 24000 5 my Value 2 2 2 2 2 3 3 3 3 3
2.3.3.4. Change Loader Constants
Select option "4. Change Loader Constants" in the "G. Change Machine Constants" menu, and the sub menu below will appear on the screen of the PC. Note: These constants are all preset from the production, but they can be changed during service as well.
The menu below shows the default values, and they can be used if the machine constants are lost. Please refer to chapter 2.8 for information on adjustment.
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PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ------------------------------------------------------CHANGE LOADER CONSTANTS ------------------------------------------------------No.Descr. Value 1. 2. 3. 4. 5. 6. 7. 8. Loader factor in 0.1mm/rev Distance to film sensor in drum (mm) Pull back length (enc. tics) Measured drum scale Wanted drum scale Unload length before cut (mm) Width (Y) maring (UM) Length (X) margin (um) 475 152 0 1000 1000 33 6000 5000
1.
Menu item 1 describes the loader factor (LF) for controlling the amount of film to be loaded into the drum. Menu item 2 describes the load distance (DTFS) from the load start until the film passes the IR sensor (IR1). Menu item 3 represents the "Pull back" function. Default value is 0, i.e. the Pull back function is not active. When active, the Pull back function pulls the film a specified number of units backwards, after the medium has been loaded and fixed with vacuum, in order to secure a good vacuum at the start of scan (zero point). Recommended values are 3-5. 1 unit corresponds to 0.5 mm.
2.
3.
4+5. Menu items 4 and 5 represent the adjustment of the scan line length accuracy in the around-drum (spinning) direction. These constants are used when film images do not register. It is recommended to measure over 820mm, i.e. the default values for item 3 and 4 are 82000.
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6.
Menu item 6 describes the amount of film to be reversed into the magazine prior to cutting the film (UBC). Menu items 7 and 8 control the margins in the X and Y direction. On the first Magnums the margins were 4 and 2 mm. On new Magnums they are 6 and 5 mm. These margins should not be changed without acceptance from R&D in Denmark.
7.
2.3.3.5. Change Misc. Constants
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 ----------------------------------------------------CHANGE MISC. DATA ----------------------------------------------------No. 1. 2. 3. 4. 5. 6. 7. Descr. Days between function test Serial number Film processor speed (cm/min) Temperature warning high level (C) Temperature error level (C) Temperature power down level (C) Bitbus delay value Value 0 xxx 48 28 32 36 3
------------------------------------------------------> Enter the menu number or 0 to exit :
1.
Menu item 1 holds information about how often the user wants the MAGNUM to perform a function test during cold starts and reboots. The default value is "0", meaning that the MAGNUM will always do a function test during reboot and cold start. Note: Purup Prepress recommends that the function test is run at a 7-day interval.
2.
In menu item 2, the serial number is equal to the machine serial number and is transmitted to the RIP. In menu item 3, the film processor speed controls the timeout values in the MAGNUM. PURUP PREPRESS A/S
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4.
Menu item 4 has information about the temperature high level warning. It is set for 28C as default. Item 5 has information about temperature error level. It is default set to 32C and will stop production with an error at this temperature. Item 6 has information about power down level. It is default set to 36C which is the critical level where the machine will perform a power down to protect from overheating vital parts. Due to the fact that the speed of the Pcs are constantly beeing increased, a programmable delay is implemented. As a guide line the list below can be used. Compaq 120Mhz Simens 50-75Mhz 25-33 Mhz PCs Slower PCs Set delay value to 3 Set delay value to 2 Set delay value to 1 Set delay value to 0
5.
6.
7.
If bitbus warnings still appear, the bitbus delay value should be increased by 1.
2.3.4. Restore and Backup
Losing the information of the configuration setup, for example due to a disk failure on the PC, could result in unneccessary production down-time while the ImageMaker is getting reconfigured and new density films are run. To minimize the production down-time, Purup recommends that you always keep an updated backup copy of your Configuration setup data stored in a safe place. If you have a backup copy of this data, you can at any time restore your Configuration setup and resume production.
2.3.4.1. Backup Procedures
During each installation of new software on the ImageMaker PC a backup copy of the Configuration setup is transferred to your Config diskette automatically. If you change one or more of the parameters in the Configuration program, a message at the bottom of the screen will ask you to update the backup copy of your Config
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diskette. To update the Config diskette, simply insert the diskette and follow the instructions on the screen. Also, whenever you have defined a new film type, changed an existing film type or made a major density adjustment in the User program, a dialog box will remind you to update the backup copy on your Config diskette. To update the Config diskette, use the "Restore and Backup" command in the Configuration Main menu. In the following sections you will find further instructions on the Backup and Restore functions. Making a Backup Copy of Configuration Setup Follow these steps: 1. Select "H. Restore and Backup" in the Configuration Main menu. The "Restore and Backup" screen image appears.
PURUP IMAGEMAKER CONFIGURATION VERSION MAGNUM 6.00 -----------------------------------------------------------RESTORE AND BACKUP -----------------------------------------------------------No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Descr. Restore Scanner Control module reference parameters. Restore Pixel Generator module reference parameters. Restore all reference parameters. Backup configuration files to Config diskette. Backup parameter files to Config diskette. Backup conf. and param. files to Config diskette. Format diskette. Restore files from Config diskette. Copy alarm and film log files to formatted diskette.
-------------------------------------------------------------> Enter the menu number or 0 to exit :
2.
Select "6. Backup conf. and param. files to Config diskette" to make a backup copy of all files. PURUP PREPRESS A/S
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When the next screen image appears, you are told to insert your "Config" diskette in the diskette drive on the PC and press the ENTER key. All configuration and parameter files are now copied to the "Config" diskette. Restoring Files from Config Diskette Follow these steps: 1. Select "H. Restore and Backup" in the Configuration Main menu. The "Restore and Backup" menu appears.
PURUP IMAGEMAKER CONFIGURATION VERSION 1.15 911029 -------------------------------------------------------------RESTORE AND BACKUP -------------------------------------------------------------No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Descr. Restore Scanner Control module reference parameters. Restore Pixel Generator module reference parameters. Restore all reference parameters. Backup configuration files to Config diskette. Backup parameter files to Config diskette. Backup conf. and param. files to Config diskette. Format diskette. Restore files from Config diskette. Copy alarm and film log files to diskette.
---------------------------------------------------------------> Enter the menu number or 0 to exit :
2.
Select "8. Restore files from Config diskette" to copy all files from the Config diskette to the PC. When the next screen image appears, you are told to insert your "Config" diskette in the diskette drive on the PC and press the ENTER key. All configuration and parameter files are now copied from the "Config" diskette.
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PURUP IMAGEMAKER MAGNUM BOOT PROCEDURE
PAGE 2.4.1
2.4. Boot Procedure

Start User program
Function test Reading config files Checking Bitbus communication Interval between F. tests is specified in Resetting system Main Program/G. Loading control programs Define machine Loading parms for PGM constants/ Change SC1 misc. constants/Days SC2 between function test. SC3 Loading master communication program Starting communication Checking HW/SW version Safety system test Starting machine clean up Clean up exposure system Clean up carriage Reboot Clean up loader & drum
User Program User Program Restart
Restart In case of trouble, first check that: the Main switch is in the I (ON) position the PC main switch is in ON position the safety key (1) is not in the OFF position Errors during Start procedure If the error occurs during the initial loading procedures (marked with above) it is recommended to go to the User Program and make a Reboot. In worst case, like e.g. BAD INIT ERROR, go to the User Program and turn off the MAGNUM. If that is not possible, turn off the MAGNUM on the main switch, wait 15 minutes and turn on the system again. Errors during Function test Note that the cause of the error must be found and corrected it could be a piece of jammed film in the MAGNUM. Use the Retry and Abort options carefully. When an error is aborted, go to the Main program and make a User control PURUP PREPRESS A/S SERVICE MANUAL
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with function test to check that the MAGNUM is ready for production.
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PURUP IMAGEMAKER MAGNUM TEST FILMS
PAGE 2.5.1
2.5. Test Films
This chapter describes the standard set of test film for the MAGNUM. These test films are used to evaluate the exposure performance of the MAGNUM. The test films are: Test film 1201 Test film 1202 Test film 1203 Test film 1204 Test film 1205 : : : : : Linearity and scaling. Density and 95% screening. Repeatability. IR Laser modulation. Density and 90% screening for 5 m (5080 dpi). Density and 90% screening for 6 m (3969 dpi). A4 geometric fit. Density and 90% screening for 8 m (3175 dpi). Multipurpose test film. Density and 90% screening for 10 m (2540 dpi). Density and 90% screening for 20 m (1270 dpi).
Test film 1206 : Test film 1207 : Test film 1208 : Test film 1209 : Test film 1210 : Test film 1220 :
2.5.1. Test Film 1201 Linearity and Scaling
Test Procedure: 1) Expose two test films 1201 in 2540 dpi on a fully adjusted MAGNUM, i.e. density, focus, and mechanical/optical adjustments have been completed. Tape the first film at each side of the film to a viewer (typically switched off), or to a white table which will provide sufficient light for this control method. See figure 2.5.1.1.
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Fig. 2.5.1.1.
2)
On top of the first film, place the second test film 1201 with the emulsion side downwards, turned 90 degrees in order to compare the horizontal scanning on the first (bottom) film with the vertical scanning on the second (top) film . See figure 2.5.1.2:
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Fig. 2.5.1.2
3)
Line up the test film with reference in point A and verify the deviation in point B. This deviation will indicate a scaling error that can be either positive or negative, and you can identify the films by checking the scan lines. The jagged scan line belongs to the bottom film and the straight scan line belongs to the top test film. Place an X 75 magnifying glass on the 820 mm line, and key in the difference between the two lines as MEASURED and WANTED values in PIM machine configuration, e.g.:
4)
NB! The dialog box is placed in upper left corner on test film 1201. Measured = 82004 5) Wanted = 82000
Make a restart of the PS-Link, an LOG OUT/IN via the SPT program, expose another set of 1201 test films and continue the above procedure until the lines overlap.
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6)
When the scaling adjustment is completed, expose another set of test films. Tape the first film as shown in figure 2.5.1.1 and place the second test film on top of it and flipped 180 degrees and with the emulsion side downwards, so that the horizontal scan lines are placed towards each other. See figure 2.5.1.3:
Fig. 2.5.1.3
Line up both test films in points A and B and check angular errors in points C and D. Verify parallellity errors in point E. The maximum deviation measured between any two lines must not exceed 2x93 m (0.186mm) mm for the machine to pass the test. This gives a maximum 93 m linearity error on a single film because the above method shows all errors a factor 2 higher than the actual error. Please refer to page 1.3.2 in this manual for further information about possible linearity and repeatability errors.
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2.5.2. Test Film 1202 Density and Screening Variation Test
This test film is used to verify the variance of the Density and Screenings values over the complete exposure area of the MAGNUM.
Figure 2.5.2.1
2.5.2.1. Procedure
1.
Open test film 1202 in StandardPageTool, select magazine, resolution 10 or 20, positive or negative and expose the job. Evaluate/measure the test film on a wiewer/densitometer by viewing/measuring the 9 check points for full density and the 95%, (or 5%, if neg.) screened area on the test film with a magnifier (x75). The dot shape must be uniform and sharp. The edge rughness of the scan lines must be 3. The screening variance must be +/- 1%. The scanline overlap must be 3. The density variance (Dmax- Dmin) must be within 0.3.
2.
Checkpoints:
See figure 2.5.2.2
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Note:
In order to evaluate the exposure performance, it is essential that the basic adjustment of the PIM is in perfect order as regards Focus values, Iris values, Power values, Density film. AND do not forget to verify the functional status of the processor as regards; Compatibility between exposure medium, chemicals, processor, temperature settings (DEV, FIX, DRYER), a.o.
4)
Transfer all related measured/evaluated data to the
Fig. 2.5.2
dialog test data box on test film 102.
Test films 1205, 1206, 1208, 1210, and 1220 can alternatively be used for the same purpose. They contain 90% screens with SERVICE MANUAL PURUP PREPRESS A/S
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frequencies from 120 l/cm (5 m resolution) to 44 l/cm (20 my resolution).
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2.5.3. Test Film 1203 Repeatability
This test film is used to verify the accuracy of positioning the carriage. The film is made up of 4 parts each adding a corner to the square during 4 successive exposures on the same film. Moreover, film 1203 contains four CMYK colour fields which give a solid black when the carriage is positioned accurately. If not, you will see a shadow effect of the text.
Fig. 2.5.3.1
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2.5.3.1. Procedure
1)
Open test film 1203 in StandardPageTool, select magazine, resolution 10 and expose the job. Display the job queue immediately after generating the expose command, and notice when the MAGNUM queue starts the exposure of film 1 by updating the percentage scale to approx. 10%. Start the SERVICE program on the MAGNUM PC and select: CONTROL+EXPOSURE+CONT.EXP.ON and answer OK in the dialog box of the Service program menu. When the PIM queue on SPT indicates that film 4 of 103/1203 is exposed approx. 10%, go to the MAGNUM PC and select: CONTROL+EXPOSURE+CONT.EXP.OFF and answer OK in the dialog box of the Service program menu. Evaluate the test film on a viewer (light table) by viewing the four check points on the test box in the centre of the test film with a magnifier. You will now see the following picture, illustrated in figure 2.5.3.2:
2)
3)
4)
5)
10
8 1/100
10
Fig. 2.5.3.2
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Under normal circumstances the two independently exposed centre scanlines will be aligned perfectly with each other but if there is any misposition it can be seen as positive or negative, and depending of the size of the mispositioning the veneer lines (2-4-6-8-10) will line up, indicating: 2 => 20m Off. 6 => 60m Off 10 => 100m Off 4 => 40my Off 8 => 80my Off
2.5.4. Test Film 1204
Handed out at Service Engineer training course.
2.5.5. Test Film 1207/1209
Handed out at Service Engineer training course. Note: This test requires special training.
2.5.6. Horisontal Start of Scan (Level 2)
For course adjustment of the horisontal start of scan expose the montage "Frame". This job consists of a 0-660 mm ruler. If this ruler starts at F.inst. 160 mm your HSOS has to be moved 160 mm to the right. (down in drum). As an added feature to all the level 2 test films you can add information directly to the dialog box by naming the SPT montage according to this simple rule: "Serial no." <space> "Initials" <space> "Comments". EXAMPLE: Name the montage: C237 CE 1209. The RIP will now place "C237" in the Serial no. field in the dialog box, "CE" in the Initials field and "1209" in the comments field.
2.5.7. The UGRA/FOGRA Digital Control Wedge
On the level 2 test films we implemented the UGRA/FOGRA digital control wedge. This control wedge can be used for additional control of the exposure quality. The wedge consists of 5 fields as shown in figure 2.5.9.1 below.
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Figure 2.5.7.1
1.
Line resolution Field 1 consists of lines, 2 pixels thick, spreading 0 -90 degrees with a spacing of 1 degree. These lines merge towards the centre and depending on the resolution of the exposure unit and the film, the lines will merge into a solid black at a certain distance from the centre. The higher the resolution, the closer to the centre the lines will form a solid black.
2.
Dot shape and size (valid in 2549 dpi only) This field consists of horisontal and vertical lines 1,2,3 and 4 pixels thick with a 1+1, 1+2, 1+3, and 1+4 relation between the number of black and white lines. The first two fields from the left all have a 1:1 relation between black and white lines and should therefore theoretically look like a 50% line screen. If, however, the dot is not round either the vertical or horisontal black lines will be thicker and a difference in the perceived grey level can be observed. The row marked "1" is a pixel field and the lines should be clearly visible. If not, either the spot is too big or the resolution of the media is too low. The remaining fields work on the same principle
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but form a 20 to 80% grey scale due to the varying number of black and white lines in each field. 3. Screen resolution Field 3 is made of 1,2,3, and 4 pixel screen dots in 45 degree angel with a spacing of 16 pixels. A correctly working unit is able to expose the 1 pixel dot in both positive AND negative. 4. Screen wedge Field 4 is a standard grey scale from 0 to 100%. The screen ruling and type is a default value determined by the chosen resolution. The measured screen percentage may vary within +/1%. 5. Screen dot overlap The last field in the UGRA/FOGRA wedge is a square 50% screen made of 1x1, 2x2, and 4x4 pixels. Due to the overlap of the beam the fields will not measure exactly 50%.
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Fig. 2.5.7.2 shows the three screens with different spot size to illustrate the principle.
Figure 2.5.7.2 Spot sizes
For the machine to be within specifications the fields should measure as follows: 1x1: 2x2: 4x4: 65 +/- 5% 57 +/- 3% 55 +/- 2%
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PAGE 2.6.1
2.6. Error Code List
:************************************************************* :* Alarmdefinition file. * :*-----------------------------------------------------------* :* Name : ALARM.LST * :* Author : Morten S. Christiansen, Purup Prepress A/S * :* Date : V 1.20 01.02.96 * :* Descr. : This file contains all definitions of alarmtexts.* :* Lines which do not contain a textdefinition must * :* begin with a ':'. * :* 07.12.95 Copied from 6.00. Error 1214 added. * :* 14.12.95 Error 5330 added. * :* 29.01.96 Error 6510 added. * :* 01.02.96 Error 1330-1332 added. * :************************************************************* : : : Errorcodes 0000H-000FH (0-15) reserved for bitbus master :************************************************************* 00001 First telegram after INIT was not from the PC 00002 Master task recieved an unrecognized interrupt 00003 Sequence error during transmission to slave. 00004 Timeout error during transmission to slave. 00005 Master received a unknown telegram from the PC. 00006 Slave does not respond to polling 00007 Command error during transmission to slave 00008 Seq.error during transmission from slave to master 00009 Poll list is full 00010 Received an unknown unexpected telegram to master. : : : Errorcodes 0010H-001FH (16-31) reserved for the kernel :************************************************************* 00016 Memory allocation error in kernel. 00017 Too many processes started in kernel. 00018 Kernel interruptroutine not properly started. 00019 Not able to open kernel initialisation file. 00020 Bad timerfactor in kernel initialisation file. 00021 Not able to open kernel statistics file. : : : Errorcodes 0020H-003FH (32-63) reserved for alarmhandler. :************************************************************* 00032 Was not able to open diagnostic information file. 00033 Bad data in diagnostic information file. 00034 Too many diagnostic descr. in diagn. info file. 00035 Not able to open translate info file.
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00036 00037 00038 00039 00040 00041 00042 00060 00061
Bad data Too many Not able Bad data Too many Too many Not able Reserved Reserved
in translate info file. data in translate info file. to open group code file. in group code file. data in group code file. alarms in buffers, overflow. to open error-logfile. for STOP message from PGM. for RUN message from PGM.
: : : Errorcodes 0040H-005FH (64-95) reserved for the debugsystem. :************************************************************* 00064 Overflow. More than 32 param. changed. Changes = 00065 Error during load of parameters. Node : 00066 Bad node number specified for parmload. Node : 00067 Not able to open parameterfile. Node : 00068 Too big parameternumber found to PGM 00069 Too big parameternumber found to SCM 00070 Bad data in SCM parmfile 00071 Bad data in PGM parmfile 00072 Too many nodes in debug change cmd. No of nodes= 00073 Invalid node in debug command. Node = 00074 Parameter change not acknowledged by slave. Node = 00075 Debug not enabled on slave. Node = 00076 Debug not disabled on slave. Node = 00077 Debug transmission error. Error code = 00078 Debug reception error. Node*256 + src = 00079 Debug received invalid param.index. Index = 00080 Debug received invalid debug status. Status code = 00081 Debug received invalid no of parms. No of parms = 00082 Not able to write to SCM parm file. Error code = 00083 Not able to write to PGM parm file. Error code = 00084 Not able to close parm file. Error code = 00085 Node in debug command not in config file. Node = 00086 Monitor not enabled on slave. Node = 00087 Monitor not disabled on slave. Node = 00088 Debug received invalid monitor status. Status = 00089 Last restore of parameters was aborted. 00090 Parameter file checksum error. Status code = 00091 No parameter file checksum detected. Status code = 00092 Last control parameter not OK. Restore ref. param. 00093 Not able to open parameter change log. 00094 Order for SCM debug invalid. Order = 00095 Index for parameter change invalid. Index = : : : Errorcodes 0060H-00FFH (96-255) reserved for the bitbussystem. :************************************************************* 00096 Received message longer than max allowed length. 00097 Received message have wrong length.
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00098 00099 00100 00101 00102 00103
Transmit fifo is floaded. Attempt to transmit too long message. Recieved message for nonexisting task. First telegram was not DATA_F DATA_N was expected, other was recieved. Internal transmission timeout in com. handler.
: : The next are reserved for bitbus master. :************************************************************* 00117 Error in bitbus master. 00118 Bitbus Master error fifo overflow. 00119 Bad node removed from poll list. Node = 00120 Poll timeout to unknown node. Node = 00121 Poll timeout to PGM. 00122 Poll timeout to BTM. 00123 Poll timeout to SC4. 00124 Poll timeout to SC5. 00125 Poll timeout to SC6. 00126 Poll timeout to SC7. 00127 Transmission timeout to unknown node. Node = 00128 Transmission timeout to PGM. 00129 Transmission timeout to BTM. 00130 Transmission timeout to SC4. 00131 Transmission timeout to SC5. 00132 Transmission timeout to SC6. 00133 Transmission timeout to SC7. 00134 Seq. error at poll to unknown node. Node = 00135 Seq. error at poll to PGM 00136 Seq. error at poll to BTM 00137 Seq. error at poll to SC4 00138 Seq. error at poll to SC5 00139 Seq. error at poll to SC6 00140 Seq. error at poll to SC7 00141 Seq. error at trans. to unknown node. Node = 00142 Seq. error at trans. to PGM. 00143 Seq. error at trans. to BTM. 00144 Seq. error at trans. to SC4. 00145 Seq. error at trans. to SC5. 00146 Seq. error at trans. to SC6. 00147 Seq. error at trans. to SC7. 00148 Too many retrans. during poll to node = 00149 Too many retrans. during poll to PGM. 00150 Too many retrans. during poll to BTM. 00151 Too many retrans. during poll to SC4. 00152 Too many retrans. during poll to SC5. 00153 Too many retrans. during poll to SC6. 00154 Too many retrans. during poll to SC7. 00155 Timeout in commandtrans. to node = 00156 Timeout in commandtrans. to PGM. 00157 Timeout in commandtrans. to BTM. 00158 Timeout in commandtrans. to SC4.
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00159 00160 00161 00162 00163 00164 00165 00166 00167 00168
Timeout in commandtrans. to SC5. Timeout in commandtrans. to SC6. Timeout in commandtrans. to SC7. Cmd-error in commandtrans. to node = Cmd-error in commandtrans. to PGM. Cmd-error in commandtrans. to BTM. Cmd-error in commandtrans. to SC4. Cmd-error in commandtrans. to SC5. Cmd-error in commandtrans. to SC6. Cmd-error in commandtrans. to SC7.
: : : Errorcodes (256-499) reserved for BIST :************************************************************* 00256 RAM error detected SC4 at address : 00257 PORT error detected SC4 at address : 00258 AD-converter error detected SC4 at channel no : 00259 DA-AD error detected SC4 at channel no : 00260 Watchdog error on SC4. 00272 Datapath error on pixelgenerator. 00273 Offset counter error on pixelgenerator. 00288 FIFO error on bitbustaxi 00289 Internal logic error on bitbustaxi. :****** 00304 Stepmotor driver error on SC4. Driver no : 00305 DC-motor driver error on SC4. Driver no : 00306 DC-driver error on SC4. Driver no : 00307 Ultra sound driver error on SC4. Driver no : :****** 00330 RAM error detected SC5 at address : 00331 PORT error detected SC5 at address : 00332 AD-converter error detected SC5 at channel no : 00333 DA-AD error detected SC5 at channel no : 00334 Watchdog error on SC5. :****** 00340 RAM error detected SC6 at address : 00341 PORT error detected SC6 at address : 00342 AD-converter error detected SC6 at channel no : 00343 DA-AD error detected SC6 at channel no : 00344 Watchdog error on SC6. :****** 00350 RAM error detected pixelgenerator at address : 00351 PORT error detected pixelgenerator at address : 00352 AD-conv. error detected pixelgen. channel no : 00353 DA-AD error detected at PGM at channel no : 00354 Watchdog error on pixelgenerator. :****** 00370 RAM error detected bitbus TAXI at address : 00371 PORT error detected bitbus TAXI at address : 00374 Watchdog error on bitbus TAXI. :******
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00380 Stepmotor driver error on SC5. Driver no : 00381 DC-motor driver error on SC5. Driver no : 00382 DC-driver error on SC5. Driver no : 00383 Ultra sound driver error on SC5. Driver no : :****** 00390 Stepmotor driver error on SC6. Driver no : 00391 DC-motor driver error on SC6. Driver no : 00392 DC-driver error on SC6. Driver no : 00393 Ultra sound driver error on SC6. Driver no : :****** 00400 Illegal module number: 00401 Unable to open parameter file for module: 00402 Error reading parameter file for module: 00403 Illegal ch. number in parameter file for module: 00404 Timeout during initbist. 00405 Unknown telegram received. BIST answer expected. 00406 Unknown error type received from BIST: 00407 Internal error in initbist. Unknown error code: 00408 Unable to load range table on module. 00409 Timeout during range table load. 00410 Timeout during range test. 00411 24V is on. Turn servicekey to NORMAL. : : : Errorcodes (500-767) reserved for the PC control task. :************************************************************* 00512 No contact to bitbus master. 00513 No contact to pixelgenerator module. 00514 No contact to bitbus TAXI module. 00515 No contact to scannercontrol module 7. 00516 No contact to scannercontrol module 4. 00517 No contact to scannercontrol module 5. 00518 No contact to scannercontrol module 6. 00519 Couldn't open file BITMAST.HEX 00520 Bad data in file BITMAST.HEX 00521 Not able to download bitbus master program. 00522 Couldn't start master communication. 00523 Spinner speed 24000 RPM not possible. 00524 Bad or missing startup file. 00525 Not able to download to node, nodeaddress : 00526 Couldn't start slave communication. Return value : 00527 Couldn't open file INITBIST.HEX 00528 Bad data in file INITBIST.HEX 00529 Not possible to download INITBIST to node : 00530 Couldn't start initbist program. Return value : 00531 Recieved unknown message during INIT-BIST 00532 Program error in INITBIST, exit program 00533 Couldn't open file SC4.HEX 00534 Bad data in file SC4.HEX 00535 Not able to download to SC4 00536 Couldn't open file SC5.HEX
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00537 00538 00539 00540 00541 00542 00543 00544 00545 00546 00547 00548 00549 00550 00551 00552 00553 00554 00555 00556 00557 00558 00559 00560 00561 00562 00563 00564 00565 00566 00567 00568 00569 00570 00571 00572 00573 00574 00575 00576 00577 00578 00579 00580 00581 00582 00583 00584 00585 00586 00587
Bad data in file SC5.HEX Not able to download to SC5 Couldn't open file SC6.HEX Bad data in file SC6.HEX Not able to download to SC6 Couldn't open file PGM.HEX Bad data in file PGM.HEX Not able to download to PGM Couldn't open file BTM.HEX Bad data in file BTM.HEX Not able to download to BTM Couldn't open file CPU2.HEX Bad data in file CPU2.HEX Not able to download to CPU2 Filmjam at position 1 Filmjam at position 2 Filmjam at position 3 Filmjam at position 4 Filmjam at position 5 Filmjam at position 6 Filmjam at position 7 Filmjam at position 8 Carriage zero point timeout. Find film order error to SC4 Filmjam, sensors indicate two films in machine Not able to check cutter position SC4 not defined, finding film impossible Laser power error during cleanup. Stop exposure error during cleanup. Carriage move error during cleanup. Carriage move to end error during cleanup. Carriage zero search error during cleanup. Vacuumvalve error during cleanup. Received illegal order from User program. Vacuum error during cleanup. Register error during cleanup. Cutting checkpos. error during cleanup. Cutting error during cleanup. Film backup error during cleanup. Tight film error during cleanup. Unload film error during cleanup. Error during module version check. Node = Magazine function test failed in section no : Hardware version error on node : Software version error on node : Filmprocessor request error. Filmprocessor not ready. Check or reset filmproc. Filmprocessor error. Filmprocessor temperature warning. Filmprocessor liquid level warning. Filmprocessor not connected.
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00588 00589 00590 00591 00592 00593 00594 00595 00596 00597 00598 00599 00600 00601 00602 00603 00604 00605 00606 00607 00608 00609 00610 00611 00612 00613 00614 00615 00616 00617 00618 00619 00620 00621 00622 00623 00625 00626 00628 00629 00630 00631 00632 :00633 00634 00635 00636 00637 00638 00639 00641
Filmprocessor not powered on. Filmprocessor jam. Data from workstation illegal, bad rollnumber = Data from workstation illegal, bad filmnumber = Data from workstation illegal, bad registertype = Data from workstation illegal, bad X-resolution = Data from workstation illegal, bad Y-resolution = Illegal manipulation field in LOOPBACK command Recieved unknown command from workstation Bad magazine no. in START from ws : Illegal obverse/reverse field in START from ws Too long filmlength spec. in START from ws Illegal pos/neg field in START from ws. Illegal resolution in START from ws. Bad high level command received from User program. Not able to stop exposure Failed moving carriage to end. Failed moving carriage relative. Not able to halt CPU2. Not able to start CPU2. Register error during start exposure. Carriage movement error during start exposure. Register error during stop exposure. Ultrasound test failed. US no = Calculation of ultrasound limits failed. Stopping exposure failed. Cassette error during cleanup. Film transport error during cleanup. Vacuum error during film transport. Vacuumvalve error during filmtransport. Register error during filmtransport. Error during stop all. All commands aborted by user. Carriage positioning/check failure. Guide sensor check failure. Waiting for film processor. Doors are open or no 24V. Close doors. No filmrolls in magazine. Error in safety system test on node : No bitbus communication response from node : Not able to open parameterfile, PARMS.DAT Bad data in parameterfile PARMS.DAT Function test prohibited while temp. out of range. Not able to open register offset def. file Commandfile not found. Bad data in commandfile. Timeout in executing command. Bad status recieved after command. Status : Film piece resident in drum. Use "RIP ONLINE". Filmroll is empty. Roll number :
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00642 00643 00644 00645 00646 00647 00648 00649 00650 00651 00652 00653 00654 00655 00656 00657 00660 00661 00662 00663 00664 00665 00666 00667 00668 00669 00670 00671 00672 00673 00674 00675 00676 00677 00678 00679 00680 00681 00682 00683 00684 00690 00691 00692 00700 00701 00702 00703 00704 00705 00706
Filmroll is empty. Job aborted. Roll number : Film in magazine 1 is not specified Film in magazine 2 is not specified Film in magazine 3 is not specified No film in mag. are big enough to cover exp. area Recieved too many START commands from workstation Startoffset and exposearea wider than carriage. Not able to set laser ON. Not able to turn laser OFF. Filmroll number 1 is empty. Filmroll number 2 is empty. Filmroll number 3 is empty. Filmroll number 1 is empty. Job aborted. Filmroll number 2 is empty. Job aborted. Filmroll number 3 is empty. Job aborted. Magazine position error. Direct positioning. Filmmagazine empty. Cassette no. = Function test failed. Exit program and restart. Data from workstation illegal, bad unit code = Data from workstation illegal, bad density field. Filmmagazine in unknown position. Film change not allowed during exposure. Register must be up before film change. Cutter at unknown position. Cut before film change Error during register position check. Status = Init module failed on node : No 24V on scanner control modules. No 24V on SCM's. Check emergency switches and PSU. Close cabinet top. Close left door. Close right door. Close front lid. Left door open or door switch fail. Right door open or door switch fail. Front lid open or lid switch fail. 24V safety relay open on node : Too many parity errors in comm. with workstation Too many errors in comm. with workstation. Illegal EXPOSE type I rec. from workstation. Illegal EXPOSE type II rec. from workstation. Illegal register type req. from workstation. Type: Runtime value error. Runtime file missing or bad. No roll definition file. Backup file read. Not able to power off Not able to open menufile for servicesystem Not able to open commandfile for servicesystem Not able to open color definition file Not able to open alarm text file Not able to open parm file Bad channel number was specified in ????
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00707 00708 00709 00710 00711 00712 00713 00714 00715 00716 00717 00718 00719 00720 00721 00722 00723 00724 00725 00726 00727 00728 00729 00730 00731 00732 00733 00734 00735 00736 00737 00738 00739 00740 00741 00742 00743 00744 00745 00746 00747 00748 00749 00750 00751 00752 00753 00754 00755 00756 00757
Error during parameter loading Not able to start communication, reset error. Unknown node address specified in load Timeout error during load. Node : File opening error during load initbist. Node : Bad data in loadfile. Node : Too many load files specified. Protocol error during load initbist. Node : Node RAC-protected during load initbist. Node : Unknown returncode during load initbist. Code : Not able to start initbist. (Ctask failed). Code : Error during transmission to BIST. Transmitcode : Unknown node number during BIST parm load. Node : Program error during RAM test. Bad node number during program load. Node : Timeout error during program load. Node : File opening err. during program load. Node : Bad data in program file. Node : Too many load programs. Protocol error during program load. Node : Node RAC-protected during program load. Node : Unknown returncode during program load. Code : Not able to open module config file Not able to open register config file Not able to open register typedef. file Bad data in register typedef. file Bad register unit no. in reg. file Not able to open machine config file Bad data in machine config file Not able to open system config file zconfig.def Downloading/starting PGM CPU2 failed Specified register type not defined Not able to delete task 6 on node : Not able to open film definition file Bad data in film definition file Not able to open roll definition file Bad data in roll definition file Not able to reset slave node. BB returncode : Not able to reset master. BB returncode : Offset error during start exposure. Spinnerspeed error during start exposure. Magazine position error during start exposure. Loading error during start exposure. Vacuum error during start exposure. Focus error during start exposure. Iris error during start exposure. Power adjust error during start exposure. Not able to start exposure, (PGM error). Vacuum error during stop exposure. Film unloading error during stop exposure. Tight film error during stop exposure.
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00758 00759 00760 00761 00762 00763 00764 00765 00766
Cutting error during stop exposure. Transport film error during stop exposure. PC was powered down without exiting program. Error during fast zero search on carriage. Error during carriage move to zero. Resolution error during scanline count. Error in scanline count. Vacuum valve error during start exposure. Vacuum valve error during stop exposure.
: : : Errorcodes (768-800) reserved for bitbus-TAXI. :************************************************************* 00768 Violation on command in comm. with workstation 00769 Parity error in communication with workstation 00770 Fifo error on BTM 00771 Tried to retransmit more than 10 times. 00772 Fifo overflow on BTM : : Errorcodes 800-820 reserved for cleanup :************************************************************* 00802 Cutter or film tight error or no film in drum. 00803 Loader error during film transport. 00804 Jam. Film cut sensor not activated. 00805 Sensor error. US1 or magsnip. 00806 Cutter error. Sensor probably stuck. 00807 Sensor error. US7. 00810 Jam. Film in belt and drum. 00811 Jam at drum end stop sensor or sensor fault. 00812 Jam at film guide or sensor fault. 00813 Jam in cutter area or loop/tight sensor fault. : : :*******************************************************************: :* Errorcodes (1024-1279) reserved for belt and vals system *: :*******************************************************************: 01024 Shaftmotor current to high. 01025 Shaftmotor current to low. 01026 Shaftmotor encoder ch.1 no connection. 01027 Shaftmotor encoder ch.2 no connection. 01028 Shaftmotor encoder zeropulse no connection. 01029 Shaftmotor encoder ch.1 shortcurcuit. 01030 Shaftmotor encoder ch.2 shortcurcuit. 01031 Shaftmotor encoder zeropulse shortcurcuit. 01032 Shaftmotor wrong direction. 01033 Shaftmotor cannot be disabled. Driver error. 01034 Shaftmotor does not turn. 01035 Beltmotor current too high. 01036 Beltmotor current too low. 01037 Beltmotor encoder ch.1 no connection. 01038 Beltmotor encoder ch.2 no connection.
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01039 01040 01041 01042 01043 01044 01045 01046 01047 01048 01049 01051 01052 01053 01054 01055 01056 01057 01058 01059 01060 01061 01062 01063 01156 01157 01158 01159 01160 01161 01162 01163 01164 01165 01166 01167 01168 01169 01170 01171 01196 01197 01198 01199 01200 01201 01210 01211 01212 01213 01214
Beltmotor encoder zeropulse no connection. Beltmotor encoder ch.1 shortcurcuit. Beltmotor encoder ch.2 shortcurcuit. Beltmotor encoder zeropulse shortcurcuit. Beltmotor wrong direction. Beltmotor cannot be disabled. Driver error. Beltmotor does not turn. Shaftmotor driver current limit. Beltmotor driver current limit. Shaftsystem received illegal order. Beltsystem received illegal order. film roller empty. No film at shaft. Film reached end-stop. Slipsensor 1 damaged. Slipsensor 2 damaged. Filmjam in beltsystem. Film is covering sensor 4,5 and 6. Film is covering sensor 4 and 5. Film is covering sensor Film is covering sensor 5,6 and 7. Film is covering sensor 6 and 7. Film is covering sensor 7. Film is covering sensor 5 or 6. Film loop sensor stuck. Stoporder is given to belt-motor. Shaftmotor received illegal order. Beltmotor received illegal order. Order for length of film is zero. Order for loaded film to long. Order for speed to beltmotor is zero. Order for speed to beltmotor to high. Order for speed to shaftmotor is zero. Order for speed to shaftmotor to high. Stoporder is given to shaftmotor. Conveyorsystem received illegal order. Filmmagazine empty or load error. Film was not cut. Filmsnip too long. Cutsensor still activated. Film did not get into conveyor, at US6. Film did not get into processor/cassette. Film has not left conveyor. No film in mag. or sens US1 error. No film at the beginning of belt.(UL4) External ligth source on IR1 in drum. Film not loaded into drum, check for jam. Loaded film too short. Minimum size is 150 mm/6''. Film in drum before load film. IR1 value = Film detected in cyl. to soon. US1 count = Belt/roller unload speed relation invalid =
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01220 01221 01222 01223 01224 01225 01226 01227 01228 01229 01230 01231 01232 01233 01250 01251 01252 01253 01254 01255 01256 01257 01258 01259 01260 01261 01262 01263 01264 01265 01266 01267 01268 01269 01270 01271 01272 01273 01274 01275 01276 01277 01278 01279
Value for sensor US1 too low. US1 value = Value for sensor IR3 too low. IR3 value = Value for sensor IR1 too low. IR1 value = Value for sensor US4 too low. US4 value = Value for sensor US5 too low. US5 value = Value for sensor US6 too low. US6 value = Value for sensor US7 too low. US7 value = Value for sensor US1 too high. US1 value = Value for sensor IR3 too high. IR3 value = Value for sensor IR1 too high. IR1 value = Value for sensor US4 too high. US4 value = Value for sensor US5 too high. US5 value = Value for sensor US6 too high. US6 value = Value for sensor US7 too high. US7 value = Order for US no film is not possible.(1-9) Order for US with film is not possible.(1-9) Output from US sensors 1,2,3 too low (< limits). Centerfrequency for US1 is zero. Check sensor. Centerfrequency for US2 is zero. Check sensor. Centerfrequency for US3 is zero. Check sensor. Centerfrequency for US4 is zero. Check sensor. Centerfrequency for US5 is zero. Check sensor. Centerfrequency for US6 is zero. Check sensor. Centerfrequency for US7 is zero. Check sensor. Centerfrequency for US driver to high. Output from US sensors 4,5,6,7 to low (< limits). No filmsnip detected at US sensor 1. US sensor 2 not connected. US sensor 3 not connected. US sensor 4 not connected. US sensor 5 not connected. US sensor 6 not connected. US sensor 7 not connected. US sensor 1 damaged. US sensor 2 damaged. US sensor 3 damaged. US sensor 4 damaged. US sensor 5 damaged. US sensor 6 damaged. US sensor 7 damaged. Order for US average not possible (1 - 2). Sensor in drum is not working ok. Remove film. Tight-sensor failed, or no film in drum. Filmmagazine is empty, remove filmsnip.
: : : : Errorcodes 0500H-05FFH (1280-1535) reserved for filmmagazine system. :************************************************************* 01280 Filmmag. motor not disabled. Curr. too high. Im= 01281 Filmmagazine motor current too high. Im =
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01282 Filmmagazine motor current too low. Im = 01283 Filmmagazine rotation direction wrong. 01284 Filmmagazine not rotating. 01285 Filmmag. sensor 2 value too high. V = 01286 Filmmag. sensor 2 value too low. V = 01287 Filmmag. sensor 1 value too high. V = 01288 Filmmag. sensor 1 value too low. V = :01289-1303 01304 Filmmag. init. failed. Can't find 1. position. :01305 01307 Filmmag. init. failed. Can't find position. :01308-1312 01313 Filmmag. order error. Invalid direction code. 01314 Filmmag. order error. Invalid length. 01315 Filmmag. order error. Invalid cassette no. :01316 01317 Filmmag. positioning failed. Can't find position. :01318 01319 Filmmag. positioning failed. Position conflict. :01320 01321 Filmmag. order error. Invalid order code. :01322 01323 Filmmag. motor error. Stepping failed. 01330 Parameter adjust failed. Adjust switch! 01331 Parameter adjust not certain. Adjust switch! 01332 Parameter adjust ok. : : : Errorcodes 0600H-06FFH (1536-1791) reserved for cutting system. :************************************************************* 01536 Illegal order for cutting system 01537 Cutter startsensor reached before end of drive 01538 Cutter endsensor reached before end of drive 01539 Cutting system sensor fault. Can't init. system 01540 Cutting system sensor fault. Can't init. system 01541 Cutting system sensor fault. Can't init. system 01542 Cutting system startsensor value too high. V = 01543 Cutting system startsensor value too low. V = 01544 Cutting system endsensor value too high. V = 01545 Cutting system endsensor value too low. V = 01546 Cutting motor rotation direction wrong 01547 Cutting motor not rotating 01548 Cutting motor current to high. I = 01549 Cutting motor current to low. I = 01550 Cutting motor not disabled. Current to high. I = 01551 Cutting system startsensor reached unexpectedly. 01552 Cutting system endsensor reached unexpectedly. 01553 Cutting system startsensor p-p value to high. Vpp= 01554 Cutting system endsensor p-p value to high. Vpp= 01555 Cutting system startsensor p-p value to low. Vpp= 01556 Cutting system endsensor p-p value to low. Vpp=
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01557 01558 01559 01560 01561 01562
Cutting Cutting Cutting Cutting Cutting Cutting
system system system system system system
sensor not found. order error. Target = actual pos. order error. Bad direction code. order error. Invalid length. position conflict. current measurement failure. Meas=
: : : Errorcodes 0700H-07FFH (1792-2047) reserved for vacuum system. :************************************************************* 01792 Vacuum relay not disabled. Relay current Ir = 01793 Vacuum sensor value 1 too high. V = 01794 Vacuum sensor value 1 too low. V = 01795 Vacuum sensor value 2 too high. V = 01796 Vacuum sensor value 2 too low. V = 01797 Vacuum not off. Vacuum = 01798 Vacuum relay current too high. Ir = 01799 Vacuum relay current too low. Ir = 01800 Vacuum not on. Vacuum = 01801 Vacuum value too high. Vacuum = 01802 Vacuum value too low. Vacuum = : : : Errorcodes 0800H-08FFH (2048-2303) reserved for aircondition system. :************************************************************* 02048 Airconditioning LIQUID signal too high. V = 02049 Airconditioning LIQUID signal too low. V = :02050 :02051 02052 Airconditioning HUMIDITY signal too high. V = 02053 Airconditioning HUMIDITY signal too low. V = :02054 :02055 02056 Airconditioning water level low. 02057 Airconditioning humidity too high. %rel : 02058 Airconditioning humidity too low. %rel : 02059 Airconditioning water level is ok. 02060 Airconditioning humidity is OK. %rel : 02070 Filter watch signal to high. V = 02071 Filter watch signal to low. V = 02072 Dust filter clogged. 02080 Airconditioning OFFLINE signal too high. V = 02081 Airconditioning OFFLINE signal too low. V = 02082 Airconditioning unit is offline. 02083 Airconditioning unit is ok. : : : : Errorcodes 0900H-09FFH (2304-2559) reserved for monitoring err. SC4. :************************************************************* 02307 Power supply overheated
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02308 No +24V supply present at SC4 02309 No +12V supply present at SC4 02310 No -12V supply present at SC4 : : : : Errorcodes 0A00H-0AFFH (2560-2815) reserved for monitoring err. SC5. :************************************************************* 02560 No +24V supply present at SC5 02561 No +12V supply present at SC5 02562 No -12V supply present at SC5 :02563-2565 02580 Check for register waste container full : : : : Errorcodes 0B00H-0BFFH (2816-3071) reserved for monitoring err. SC6. :************************************************************* 02818 No +24V supply present at SC6 02819 No +12V supply present at SC6 02820 No -12V supply present at SC6 : : : : Errorcodes 0C00H-0CFFH (3072-3327) reserved for safety system. :************************************************************* 03072 Safety loop opened at PGM 03073 Safety loop opened at SC4 03074 Safety loop opened at SC5 03075 Safety loop opened at SC6 03076 Safety loop opened at power supply 03077 Safety system disabled 03078 Safety loop opened at right end stop 03079 Safety loop opened at left end stop : : : : Errorcodes (3318-3583) reserved for register system. :************************************************************* 03318 Register unit motor current too high. I = 03319 Register unit motor current too low. I = 03320 Register unit hall sensor value too high. V = 03321 Register unit hall sensor value too low. V = 03322 Reg. unit hall sensor p-p value too high. Vpp = 03323 Reg. unit hall sensor p-p value too low. Vpp = 03324 Reg. unit motor driver current too high. I= 03325 Register unit positioning conflict. :****** 03397 Register system error. Register no. = 03398 Register system recieved illegal order 03399 Register system time out error. Register no. =
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: : : Errorcodes 0E00H-0EFFH (3584-3839) reserved for spinner system. :************************************************************* 03584 Spinner motor does not start 03585 Spinner motor RPM to high 03586 Spinner motor RPM to low 03587 Spinner driver overheated 03588 Spinner encoder no connection 03589 Spinner encoder shortcircuit 03590 Test probe 1 no connection 03591 Test probe 2 no connection 03592 Test probe 1 shortcircuit 03593 Test probe 2 shortcircuit 03594 Test probe not connected 03595 Spindle position command out of range 03596 Not able to create task on PGM. 03597 Command not recognized by PGM. Command = 03598 Bad number of rs-lines in command. 03599 Fifo write error during start exposure. 03600 RIP transm. more lines than spec. Job aborted. 03601 Carriage zero point not accurate on first film. 03602 Carr. zero point not accurate on subsequent films. 03603 No 24V present on PGM. Check powersupply. 03604 Low output on left hall-element. 03605 Spinnerspeed too high at 24000. RPM = 03606 Spinnerspeed too low at 24000. RPM = 03607 Spinnerspeed too high at 12000. RPM = 03608 Spinnerspeed too low at 12000. RPM = 03609 Spinnermotor does not run. 03610 Spinner killed. Use start spinner cmd. 03611 Bad resolution in command. Res = 03612 No phase lock signal. 03613 Spinner phaselock error or no 24V. : : : : Errorcodes 0F00H-0FFFH (3840-4095) reserved for spindel system. :************************************************************* 03840 Hall sensor left side carriage no connection 03841 Hall sensor right side carriage no connection 03842 Hall sensor left side carriage shortcircuit 03843 Hall sensor right side carriage shortcircuit 03844 Hall sensor left side carriage no response 03845 Hall sensor right side carriage no response 03846 Spindle motor does not turn 03847 Spindle motor runs wrong direction 03848 Spindle driver overheated 03849 Spindle encoder channel 1 no connection 03850 Spindle encoder channel 2 no connection 03851 Spindle encoder channel 1 shortcircuit
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03852 03853 03854 03855 03856 03860 03861 03862 03863 03864 03865 03866 03867 03868 03869 03870 03871 03872 03873 03874 03875 03876 03877 03878 03881 03882 03883 03884 03885 03886 03887 03888 03891 03892 03893 03894 03895 03896 03897 03898 03899
Spindle encoder channel 2 shortcircuit Spindle position error. Reached endstop. Carriage left endstop reached. Carriage right endstop reached. Carriage right endstop reached. Spindle start/stop syncronizer error. Jam at guide detected. Spindle is loosing steps, or wrong speed. Speed : Spindle stop timeout at stop expose. CPU2 communication error. Carriage left hall sensor edge not found. Carriage left hall sensor limit not found. Mechanical zero sensor constant activated. No response from mechanical zero sensor. Mechanical zero sensor hysteresis too big. Carriage temperature correction warning. Left hall element low output at zero point. Fifo error in the exposure system. Special RW cannot run on this HW revision. IR interrupter width to big. W(um) = IR interrupter width to small. W(um) = Distance from IR to My-Com to long. D(um) = Distance from IR to My-Com to short. D(um) = My-Com sensor hysteresis to big. H(um) = Error finding left IR switch. SensCode = Couldn't find left IR left edge. SensCode = Error in zero-search procedure. SensCode = Couldn't find My-Com sensor. SensCode = My-Com hysteresis too big. SensCode = Error in zero-search procedure. SensCode = My-Com hysteresis too big. SensCode = Failed driving to start point. SensCode = Error finding left IR switch. SensCode = Couldn't find left IR right edge. SensCode = Error in zero-search procedure. SensCode = Couldn't find left IR left edge. SensCode = Error in zero-search procedure. SensCode = Couldn't find My-Com sensor. SensCode = My-Com hysteresis too big. SensCode = My-Com hysteresis too big. SensCode = Failed driving to start point. SensCode =
: : : : Errorcodes 1000H-10FFH (4096-4351) reserved for laser system. :************************************************************* 04096 Temperature sensor no connection 04097 Temperature sensor shortcircuit 04098 Laser diode temperature too high, regulation error 04099 Laser diode temperature too low, regulation error 04100 Laser diode power monitor damaged
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04101 04102 04103 04104 04105 04106 04107 04108 04109 04110 04111 04112 04113 04114 04115 04116 04117 04118 04119 04120 04121 04122 04150 04151 04152 04153
Laser diode current sense damaged Laser current too high Laser current too low PSD channel 1 shortcircuit PSD channel 2 shortcircuit PSD channel 3 shortcircuit PSD channel 4 shortcircuit PSD channel 1 no connection PSD channel 2 no connection PSD channel 3 no connection PSD channel 4 no connection Bad laserpower specified in command Laser diode temperature too high or too low. Bad peltier current spec. in command. No or low current signal from ARION laser. ARION laser getting worn out. Diode temp. not stable. Test not executed. Laser diode not connected or burned out. Laser diode is getting worn out. Noise on laser diode temp. measurement. Laser func.test cannot run on this HW revision. Clean or replace ARION laser dustfilter. Configuration values for laser are bad. Laser function test timeout. Laser func. test aborted. Doors must be closed. Not able to close laser shutter.
: : : : Errorcodes 1100H-11FFH (4352-4607) reserved for iris adjust system. :************************************************************* 04352 Current iris position beyond max. limit 04353 Current iris position below zero 04354 Iris target position beyond max. limit 04355 Iris target position below zero 04356 Invalid order code for iris task 04357 Iris zero sensor not found 04359 Iris zero search failed. X1 not found 04361 Iris zero search failed. X2 not found 04362 Iris position parameter error 04363 Iris position value error 04364 Iris direction code invalid 04365 Iris rot. sensor detector value measure failure. 04366 Iris zero sensor failure. Value too high : Vout = 04367 Iris zero sensor failure. Value too low : Vout = :04368 04369 Iris rot. sensor failure. Value too high : Vout = 04370 Iris rot. sensor failure. Value too low : Vout = 04371 Iris error. Motor doesn't rotate :04372-4374 04375 Iris position value beyond range
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04376 04377 04378 04379 04380 04381 04382 04383 04384 04385 04386 04387
Iris position value below range Iris zero sensor peak-peak value too high. Vpp = Iris zero sensor peak-peak value too low. Vpp = Iris rot. sensor peak-peak value too high. Vpp= Iris rot. sensor peak-peak value too low. Vpp = Iris reached physical end during init. Continues. Iris end stop detected. Direction = No iris end stop detected. Vdiff = Iris end stop found in working area. Dist = No iris zero stop detected. Vdiff = Iris zero stop found in working area. Dist = Iris sensor/motor error in function test.
: : : Errorcodes 1200H-12FFH (4608-4863) reserved for focus adjust system. :************************************************************* 04608 Current focus position beyond max. limit 04609 Current focus position below zero 04610 Focus target position beyond max. limit 04611 Focus target position below zero 04612 Invalid order code for focus task 04613 Focus ref. sensor not found 04615 Focus zero search failed. X1 not found 04616 Focus zero search fail. No falling edge found. 04617 Focus zero search failed. X2 not found :04619 04620 Focus direction code invalid 04621 Focus position error. Ref. sensor detected 04622 Focus ref. sensor failure. Value too high : Vout = 04623 Focus ref. sensor failure. Value too low : Vout = 04624 Focus position error. End sensor detected 04625 Focus end sensor failure. Value too high : Vout = 04626 Focus end sensor failure. Value too low : Vout = :04627-4630 04631 Focus position value beyond range 04632 Focus position value below range 04634 Focus ref sensor peak-peak value too high. Vpp = 04635 Focus ref sensor peak-peak value too low. Vpp = 04636 Focus end sensor peak-peak value too high. Vpp = 04637 Focus end sensor peak-peak value too low. Vpp = 04638 Drive towards spinner prohibited. Make func. test. 04639 Focus rot. sensor failure. Value too high : Vout = 04640 Focus rot. sensor failure. Value too low : Vout = 04641 Focus error. Motor doesn't rotate 04642 Focus ref. sensor limit value too low : Vout = 04643 Focus end sensor limit value too high : Vout = 04644 Focus rot. sensor detector value measure failure. 04645 Focus rot. sensor peak-peak value too high. Vpp= 04646 Focus rot. sensor peak-peak value too low. Vpp = 04647 Focus reached physical end during init. Continues. :
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: Errorcodes 1300H-13FFH (4864-5119) reserved for TAXI-transmission. :************************************************************* : : : Errorcodes 1400H-15FFH (5120-5631) reserved for the userinterface. :*************************************************************** 05120 Not able to open menudescriptor file MENU.DES 05121 Bad data in menudescriptor file MENU.DES 05122 Not able to open picture file. 05123 Bad data in picture file. 05124 Not able to open alarmmessages file ALARM.TXT 05125 Received alarm with not defined text : 05126 Bad data in file ALARM.TXT 05127 Not able to open icon file : 05128 Bad data in icon file : 05129 Not able to open menutext file MENU.TXT 05130 Bad data in menutext file MENU.TXT 05131 Not able to open help text file HELP.TXT 05132 Bad data in help text file HELP.TXT 05133 Not able to open manual file MANUAL.TXT 05134 Bad data in manual file MANUAL.TXT 05135 Not able to allocate memory for picture data 05136 Mouse damaged or not connected 05137 Not able to read menu file. 05138 Not able to read main menu file. 05139 Not able to read background menu file. 05140 Error in read of command data dialogbox. 05141 Error in read of command dialogbox. 05142 Software installation is not OK. 05143 Not able to open quickref. def. file. 05144 Bad data in quickref. def. file. 05145 Helptext file not found. 05147 Not able to open unit definition file. 05148 Error in saving units. 05149 Bad data in unit file. 05160 Error in AD-Conversion. Status = 05161 Error in speed measurement. Status = 05170 Machine control is busy. 05171 No dialogbox for showerror. (show.dia). 05172 No dialogbox for errorhelp. (errhlp.dia). 05173 No dialogbox for error-illustration (errillu.dia). 05174 No dialogbox for servicedata.(servdata.dia). 05175 Error in opening menufile. (File not found). 05180 Error in loading additional fonts. Fcount = 05181 Error in unit conversion. Id = 05182 Error in resolution flag. Flag = 05190 Not able to open helpillu.def 05200 Carriage length must be a positive value. 05201 Move carriage length to high. 05202 Filmtype is not defined. 05203 Carriage movement too long.
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05204 Carriage movement order not possible. 05206 Other order is running, not able to cut film. 05207 Not able to change film when door is open. 05208 Not able to turn magazine when door is open. 05209 Input-value must not be zero. 05210 Input-value to to high. 05211 Wanted density lower than def. density range. 05212 Wanted density not within def. density range. 05213 Selected linenumber has to be from 1 to 10. 05214 Negative slope is not allowed in input values. 05215 No filmtype has been selected. :****** 05300 Error in dialog box definition. String no. : 05301 Eject film is not allowed during film exposure. 05302 Input value(s) violates limits. Try again... 05303 Can't execute cmd-file while running user order. 05304 Bad result data line in command file. 05305 No data file for filmprocessor test. 05306 Bad data in filmprocessor data file. 05307 Error in turning the cassette motor. 05308 The cassette is full or not mounted. 05309 Error in the loader system. 05310 Not able to open filmlog file. 05311 Not able to open errorlog file. 05312 Not able to open alarmlog file. 05313 Date not found in the film log file. 05314 Parameter log file is empty. 05315 Error in configurations files. 05316 Error in configurations files. 05317 Illegal resolution cmd. from RIP. 05320 Error during forced bitmap exposure. 05330 Error during offset/register film. : 05400 Density input value out of range. 05401 Laser power value out of range. 05402 Wanted density out of range. 05403 Density values are not increasing. 05404 Large laser power adjustment. : : : Errorcodes 1600H-16FFH (5632-5887) reserved for Command ctrl. :*************************************************************** 05632 Command control 4 error. Can't create task. 05633 Command control 4 error. Task(s) running. Task ID= 05634 Command control 4 error. Invalid command. Command= 05642 Command control 5 error. Can't create task. 05643 Command control 5 error. Task(s) running. Task ID= 05644 Command control 5 error. Invalid command. Command= 05652 Command control 6 error. Can't create task. 05653 Command control 6 error. Task(s) running. Task ID= 05654 Command control 6 error. Invalid command. Command=
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05662 Command control 7 error. Can't create task. 05663 Command control 7 error. Task(s) running. Task ID= 05664 Command control 7 error. Invalid command. Command= : : : : : Errorcodes 1700H-17FFH (5888-6143) reserved for Expose ctrl. :*************************************************************** 05888 Error during stop exposure (Not able to start) : : : : : Errorcodes 1800H-18FFH (6144-6399) reserved for misc. SC4 :*************************************************************** 06144 Misc.4 task invalid order code. Order = 06146 Door emergency switch value too high. V = 06147 Door emergency switch value too low. V = 06150 Invalid order code for monitor 4 : : : : Errorcodes 1900H-19FFH (6400-6655) reserved for misc. SC5 :*************************************************************** 06400 Misc.5 task invalid order code. Order = 06401 PROREQUEST failure. Current too high. I = 06402 PROREQUEST not removed. Current too low. I = 06403 PROREQUEST not set. Current too high. I = 06404 PROFIN value too high. V = 06405 PROFIN value too low. V = 06406 PROTEMP value too high. V = 06407 PROTEMP value too low. V = 06408 PROLEV value too high. V = 06409 PROLEV value too low. V = 06410 PROJAM value too high. V = 06411 PROJAM value too low. V = 06412 Filmprocessor not finished. 06413 Invalid order code for monitor 5. 06414 PROCON value too high. V = 06415 PROCON value too low. V = 06416 PROREADY value too high. V = 06417 PROREADY value too low. V = 06500 Temperature in cylinder to low. T (C) = 06501 Temperature in cylinder to high. T (C) = 06502 Temperature in cylinder air to low. T (C) = 06503 Temperature in cylinder air to high. T (C) = 06504 Temperature in cylinder is very low. T (C) = 06505 Temperature in cylinder is very high. T (C) = 06506 Cylinder temperature sensor value too high. V = 06507 Cylinder temperature sensor value too low. V =
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06508 Air temperature sensor value too high. V = 06509 Air temperature sensor value too low. V = 06510 Power down because temp. is very high. T (C) = : : : : Errorcodes 1A00H-1AFFH (6656-6800) reserved for misc. SC6 :*************************************************************** 06656 Misc.6 task invalid order code. Order = 06657 Invalid order code for monitor 6. 06658 Power off signal current too high. I = 06659 Power off signal current too low. I = 06660 PC boot signal current too high. I = 06661 PC boot signal current too low. I = : : Errorcodes (6800-6911) reserved for misc. SC7 :*************************************************************** 06800 Misc.7 task invalid order code. Order = 06801 Invalid order code for monitor 7. : : : : : Errorcodes 1B00H-1BFFH (6912-7166) reserved for casette. SC6 :*************************************************************** 06912 Cassette motor not disabled. Current too high. Ic = 06913 Cassette motor current too high. Ic = 06914 Cassette motor current too low. Ic = 06915 Cassette rotation direction wrong. 06916 Cassette not rotating. 06917 Cassette order error. Invalid order code. 06918 Cassette order error. Invalid direction order. 06919 Cassette order error. Length not possible. 06920 Cassette is full. 06921 Cassette is connected. 06922 The cassette is not connected. 06923 Cassette turn length is zero. 06924 Cassette turn length value to high. 06925 Cassette switch wrong connection. Vc = 06926 Film did not get into cassette. Remove film. 06927 Two films in machine. Remove film from conveyor. : : : : : Errorcodes (7168-7300) reserved for find_film SC4 :*************************************************************** 07168 More than one film in machine. Remove films. 07169 Jam!!. More than one film in conveyor. 07170 Jam!!. More than one film in drum. 07171 Invalid order code for find_film task.
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07172 Film in belt and over belt. 07173 Film in belt and over belt. 07174 Film did not get into processor/cassette. : : : Errorcodes (7300-7423) reserved for find_film SC7 :*************************************************************** 07300 Invalid order code for find_film task. : : Errorcodes 1D00H-1DFFH (7424-7679) reserved for vacuum valve SC6 :*************************************************************** 07424 Vacuum valve motor current too high. I = 07425 Vacuum valve motor current too low. I = 07426 Vacuum valve hall sensor A value too high. V = 07427 Vacuum valve hall sensor A value too low. V = 07428 Vacuum valve hall sensor B value too high. V = 07429 Vacuum valve hall sensor B value too low. V = 07430 Vac.valve hall sensor A p-p value too high. Vpp= 07431 Vac.valve hall sensor B p-p value too high. Vpp= 07432 Vacuum valve hall sensor A p-p value too low. Vpp= 07433 Vacuum valve hall sensor B p-p value too low. Vpp= 07434 Vacuum valve motor current too high. I= 07435 Vacuum valve positioning conflict. 07436 Vacuum valve system recieved illegal order 07437 Vacuum valve time out error. 07438 Vacuum valve function test failure. 07439 Vacuum valve positioning failure. : : Errorcodes 1E00H-1EFFH (7680-7935) reserved for voltage/WD check :*************************************************************** 07680 SC4 +12V voltage too high. V= 07681 SC4 +12V voltage too low. V= 07682 SC4 -12V voltage too high. V= 07683 SC4 -12V voltage too low. V= 07684 SC4 24V voltage too high. V= 07685 SC4 24V voltage too low. V= 07686 SC4 5V voltage too high. V= 07687 SC4 5V voltage too low. V= 07688 SC4 1.23V voltage too high. V= 07689 SC4 1.23V voltage too low. V= 07690 SC4 WD has reset module. Safety relay status = 07691 SC4 module reset. 07692 SC4 bitbus net timeout. No. of timeouts = 07693 24V failure on SC4. : 07700 SC5 +12V voltage too high. V= 07701 SC5 +12V voltage too low. V= 07702 SC5 -12V voltage too high. V= 07703 SC5 -12V voltage too low. V= 07704 SC5 24V voltage too high. V= 07705 SC5 24V voltage too low. V=
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PAGE 2.6.25
07706 07707 07708 07709 07710 07711 07712 07713 :
SC5 SC5 SC5 SC5 SC5 SC5 SC5 24V
5V voltage too high. V= 5V voltage too low. V= 1.23V voltage too high. V= 1.23V voltage too low. V= WD has reset module. Safety relay status = module reset. bitbus net timeout. No. of timeouts = failure on SC5.
07720 SC6 +12V voltage too high. V= 07721 SC6 +12V voltage too low. V= 07722 SC6 -12V voltage too high. V= 07723 SC6 -12V voltage too low. V= 07724 SC6 24V voltage too high. V= 07725 SC6 24V voltage too low. V= 07726 SC6 5V voltage too high. V= 07727 SC6 5V voltage too low. V= 07728 SC6 1.23V voltage too high. V= 07729 SC6 1.23V voltage too low. V= 07730 SC6 WD has reset module. Safety relay status = 07731 SC6 module reset. 07732 SC6 bitbus net timeout. No. of timeouts = 07733 24V failure on SC6. :****** 07742 Fuse for laser PSU blown. 07743 Fuse for airconditioning unit blown. 07751 SC4 module reset check. Init_flag = 07752 SC5 module reset check. Init_flag = 07753 SC6 module reset check. Init_flag = 07754 SC7 module reset check. Init_flag = :****** 07760 SC7 +12V voltage too high. V= 07761 SC7 +12V voltage too low. V= 07762 SC7 -12V voltage too high. V= 07763 SC7 -12V voltage too low. V= 07764 SC7 24V voltage too high. V= 07765 SC7 24V voltage too low. V= 07766 SC7 5V voltage too high. V= 07767 SC7 5V voltage too low. V= 07768 SC7 1.23V voltage too high. V= 07769 SC7 1.23V voltage too low. V= 07770 SC7 WD has reset module. Safety relay status = 07771 SC7 module reset. 07772 SC7 bitbus net timeout. No. of timeouts = 07773 24V failure on SC7. : 07900 PGM module has been reset. 07901 24V failure on PGM. : : : Errorcodes 2000H-203FH (8192-8255) reserved for helplib SCM's
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:*************************************************************** 08192 Can't create interrupt dummy task. Status = 08193 Interrupt control bit PT1 was not set. : : : Errorcodes 2040H-20FFH (8256-8447) reserved communication test :*************************************************************** :08256-8367 : : : Errorcodes for low level errors :*************************************************************** 08500 Modem input buffer overflow. 08501 Error reading texts. 08502 Couldn't read normtext.def. 08503 Bitbus telegram too long. 08504 Illegal bitbus node. 08505 Bitbus telegram too long. 08506 Internal telegram buffer overflow. 08507 Internal telegram buffer underflow. : : Errorcodes for FilmMeter. :*************************************************************** 08600 Error during FilmMeter configuration check. 08601 Too many A4-pages to FilmMeter. A4-pages = 08602 Timeout in FilmMeter communication. : : Errorcodes for spinner. :*************************************************************** 09997 Spinner stop failed. 09998 Spinner speed command failed. 09999 Spinner start failed.
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PURUP IMAGEMAKER MAGNUM CONTROL PARAMETERS
PAGE 2.7.1
2.7. Control Parameters
The parameters are an area with different variables and constants that cannot be changed from the configuration program. The parameters have different information, however, all information is closely connected to the hardware, mechanical, optical, and electronic parts. The parameters can be divided into two groups: 1. Minimum and maximum values. E.g. minimum and maximum allowed limits for a hall element (sensor). These values are fixed by Purup Prepress R&D. Sensor limits. E.g. a limit that determines whether the cutting wheel is placed at a sensor. These limits are generated during the function test. The software has three sets of parameters. A set of parameters consists of a file for the scanner control modules and a file for the pixel generator module. The files are named ACTSCM.XXX and ACTPGM.XXX, where the XXX is the file extension that indicates the type of set in question. Extensions are PAR, REF, and RF1. The three sets of parameters are briefly described: .RF1 files: This parameter file is not machine dependant. This parameter file that can only be the basis for an intial function test, i.e. this file only contains group 1 parameters. .REF files: This parameter file is machine dependant, and it is not generated till after an initial function test. Therefore, the file contains parameters of type 1 as well as type 2. See also chapter 2.7.2 and 2.7.3 The file is only used as backup and can be used in the configuration program. .PAR files: This parameter file is machine dependant, and it contains the daily working parameters. At RESTORE in the configuration program the parameters are written over by the .REF files. The file is read when the control program is started and written when it is
2.
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completed. The .RF1 files can only be used during an initial function test. The .PAR files are the most exposed files. They can on rare occasions be destroyed if, e.g. the PC is disconnected while the files are updated. If the parameters are destroyed, exit to the Main program, enter the configuration program, choose restore of parameters, exit, and restart the program.
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PAGE 2.7.3
2.7.1. Missing Parameters
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2.7.2. SCM Parameter List
:********************************************************** :* ACTSCM.RF1 :* Version 1.21 29.05.96 Morten S. Christiansen :* Purup Prepress A/S :* This file contains the default parameters for :* ELEFANT initial start up. :* :* 07.12.95 Copied from 6.00. :* Param. 94 added. :* 29.01.96 Param 6 and 14 incr. from 100 to 2000. :* Param 91 incr. from 125 to 200. :* Param 95-99 added. :* 01.02.96 Param 613 incr. from 3000 to 5000. :* 29.05.96 Param 308,309 changed from 500,20 to 1000,40. :********************************************************** 00000 33333 Control parameter for security : :********************************************************** :* Values for scannercontrol 4 :********************************************************** : Roller motor parameters 00001 00100 ROL_EN_DEL 00002 50000 ROL_MAX_EN 00003 00000 ROL_MIN_EN 00004 50000 ROL_MAX_DIS 00005 00000 ROL_MIN_DIS 00006 02000 ROL_DIS_DEL 00007 50000 ROL_MAX_CUR 00008 20000 ROL_DIR_DEL : : Belt motor parameters 00009 00100 BEL_EN_DEL 00010 50000 BEL_MAX_EN 00011 00000 BEL_MIN_EN 00012 50000 BEL_MAX_DIS 00013 00000 BEL_MIN_DIS 00014 02000 BEL_DIS_DEL 00015 50000 BEL_MAX_CUR 00016 20000 BEL_DIR_DEL : : Loop regulation faktors
* * * * * * * * * * * * *
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00017 00070 REG_FAKTOR : : Encoder test values 00018 01000 ENC_MAX 00019 00000 ENC_MIN : : US/IR sensor limits 00020 00000 US1_LIM 00021 00000 US1_START 00022 00300 US1_INIT 00023 00000 IR1_LIM 00024 00000 IR1_START 00025 00040 IR1_INIT 00026 00000 US6_LIM 00027 00000 US6_START 00028 00300 US6_INIT 00029 00000 US7_LIM 00030 00000 US7_START 00031 00100 US7_INIT 00032 00000 IR3_LIM 00033 00000 IR3_START 00034 00040 IR3_INIT : : Load sequence timelimits 00040 00000 LOAD_WAIT_MAX 00041 00100 UL_WAIT_LIM : : Nofilm measured amplitudes 00042 00000 AMP_US1 00043 00000 AMP_IR1 00044 00000 AMP_US6 00045 00000 AMP_US7 00046 00000 AMP_IR3 : : High/low limits 00050 00500 US1_LLIM 00051 04000 US1_HLIM 00052 00000 IR1_LLIM 00053 00050 IR1_HLIM 00054 00500 US6_LLIM 00055 04000 US6_HLIM 00056 00500 US7_LLIM 00057 04000 US7_HLIM 00058 00000 IR3_LLIM 00059 00050 IR3_HLIM : 00060 00002 US_D1_AMP
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PAGE 2.7.7
00061 00150 US_CENT1_FREQ : : Trig level for IR 00062 00010 IR1_TRIG 00063 00005 IR1_DYNAMIC 00064 00010 IR3_TRIG 00065 00005 IR3_DYNAMIC : : Values for the loader system */ 00070 00150 LENGTH_UNLOAD 00071 00100 LENGTH_TRANSPORT 00072 01000 LENGTH_LOAD1 00073 00300 LENGTH_US_LOAD 00074 00700 LENGTH_TIGHT 00075 00200 LENGTH_AWAY_FILM 00076 00200 LENGTH_CATCH_FILM 00077 00200 LENGTH_INIT_FILM 00078 00030 LENGTH_BACK_FILM 00079 00005 PROC_WAIT_LIM 00080 01500 NO_FILM_US6 00081 00020 MAG_BACK_FILM 00082 01000 SLIP_AWAY_LGT 00083 00325 SLOW_COUNT 00084 00600 SPEED_FACTOR 00085 00600 SPEED_PROC 00086 00700 HIGH_SPEED 00087 00000 STATICC_US6 00088 00150 DYNAMC_US6 00089 00000 CONTROL_CUT_OVER 00090 02500 LENGTH_HISPEED 00091 00200 LOOP_CHECK 00092 02185 FILMSTOP_CHECK 00093 00000 FILMSTOP_ACTIVE 00094 00089 BR_UNL_REL_FACT 00095 00070 REG_FACTOR_2 00096 00001 TIGHTHOLD 00097 00000 TIGHT_BEF_UNLOAD 00098 00089 BR_LOAD_REL_FACT 00099 00000 ENCODERS_OFF : : Limits for cut/slip sensors 00100 03000 SLIP_HLIM 00101 00050 SLIP_LLIM 00102 00450 SLIP_TRIG 00103 03000 CUTS_HLIM 00104 00050 CUTS_LLIM 00105 00450 CUTS_TRIG
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: : Handling speeds 00110 00325 HASP_IN_0 00111 00250 HASP_IN_1 00112 00200 HASP_IN_2 00113 00500 HASP_OUT_0 00114 00400 HASP_OUT_1 00115 00325 HASP_OUT_2 00116 01200 HASP_TIGHT 00117 00500 HASP_UNLOAD : /* Lock parametres */ 00120 00000 LOCK1_POS 00121 00000 LOCK2_POS 00122 00000 LOCK3_POS 00123 00000 LOCK4_POS 00124 00000 LOCK5_POS 00125 00000 LOCK6_POS 00126 00000 LOCK7_POS 00127 00000 LOCK8_POS 00128 00000 LOCK9_POS 00129 00000 LOCK10_POS 00130 00000 LOCK11_POS 00131 00000 LOCK12_POS 00132 00000 LOCK13_POS 00133 00000 LOCK14_POS 00134 00000 LOCK15_POS 00135 00010 LOCK1_TOP_LIM 00136 00010 LOCK2_TOP_LIM 00137 00010 LOCK3_TOP_LIM 00138 00010 LOCK4_TOP_LIM 00139 00010 LOCK5_TOP_LIM 00140 00010 LOCK6_TOP_LIM 00141 00010 LOCK7_TOP_LIM 00142 00010 LOCK8_TOP_LIM 00143 00010 LOCK9_TOP_LIM 00144 00010 LOCK10_TOP_LIM 00145 00010 LOCK11_TOP_LIM 00146 00010 LOCK12_TOP_LIM 00147 00010 LOCK13_TOP_LIM 00148 00010 LOCK14_TOP_LIM 00149 00010 LOCK15_TOP_LIM 00150 00040 LOCK1_EDGE_LIM 00151 00040 LOCK2_EDGE_LIM 00152 00040 LOCK3_EDGE_LIM 00153 00040 LOCK4_EDGE_LIM 00154 00040 LOCK5_EDGE_LIM
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PAGE 2.7.9
00155 00156 00157 00158 00159 00160 00161 00162 00163 00164 00165 00166 00167 00168 00169 00170 00171 00172 00173 00174 00175 00176 00177 00178 00179 00180 00181 00182 00183 00184 00185 00186 00187 00188 00189 00190 00191 00192 00193 00194 00195 00196 00197 00198 00199 00200 00201
00040 00040 00040 00040 00040 00040 00040 00040 00040 00040 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00000 00300 00300 05000 05000 00000 02000 00050
LOCK6_EDGE_LIM LOCK7_EDGE_LIM LOCK8_EDGE_LIM LOCK9_EDGE_LIM LOCK10_EDGE_LIM LOCK11_EDGE_LIM LOCK12_EDGE_LIM LOCK13_EDGE_LIM LOCK14_EDGE_LIM LOCK15_EDGE_LIM LOCK1_HLIM LOCK2_HLIM LOCK3_HLIM LOCK4_HLIM LOCK5_HLIM LOCK6_HLIM LOCK7_HLIM LOCK8_HLIM LOCK9_HLIM LOCK10_HLIM LOCK11_HLIM LOCK12_HLIM LOCK13_HLIM LOCK14_HLIM LOCK15_HLIM LOCK1_LLIM LOCK2_LLIM LOCK3_LLIM LOCK4_LLIM LOCK5_LLIM LOCK6_LLIM LOCK7_LLIM LOCK8_LLIM LOCK9_LLIM LOCK10_LLIM LOCK11_LLIM LOCK12_LLIM LOCK13_LLIM LOCK14_LLIM LOCK15_LLIM LOCK_DIS_DEL LOCK_EN_DEL LOCK_MAX_DIS LOCK_MAX_EN LOCK_MIN_EN LOCK_HALL_HLIM LOCK_HALL_LLIM
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00202 00020 LOCK_LCONST 00203 02000 LOCK_TOUT 00204 02000 LOCK_TOUT_T 00205 00080 LOCK_MIN_VPP : :/* Vacuum parameters */ 00218 05000 VAC_MAX_DIS 00219 05000 VAC_MAX_EN 00220 00000 VAC_MIN_EN 00221 00300 VAC_DIS_DEL 00222 00300 VAC_EN_DEL 00223 00100 VACUUM_OFF 00224 00000 VACUUM_MIN 00225 05000 VACUUM_MAX 00226 00000 VACUUM_ON 00227 00000 VACUUM_VAL 00228 00000 VAC_OFFSET 00229 01000 VAC_ON_DEL 00230 01000 VAC_OFF_DEL 00231 00032 VAC_OFF_C 00232 00000 VAC_MIN_REF : :/* Emergency sensor parameters */ 00242 05000 EM_DOOR_HLIM 00243 00000 EM_DOOR_LLIM 00244 01000 EM_DOOR_TRIG 00245 00200 EM_TOP_TRIG : :/**********************************************************/ :/* Values for scannercontrol 5 */ :/**********************************************************/ : :/* Filmcutter parameters */ 00300 00000 CUT_POS 00301 00000 CUT_ENC_COUNT 00302 06700 CUT_DIST_REF 00303 06700 CUT_MAX_DIST 00304 05000 CUT_MAX_DIS 00305 00150 CUT_MAX_EN 00306 00000 CUT_MIN_EN 00307 00500 CUT_DIS_DEL 00308 01000 CUT_EN_DEL 00309 00040 CUT_ENC_DEL : :/* Film processor parameters */ 00340 00300 PRORQ_EN_DEL 00341 00300 PRORQ_DIS_DEL
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PAGE 2.7.11
00342 05000 PRORQ_MAX_DIS 00343 05000 PRORQ_MAX_EN 00344 00000 PRORQ_MIN_EN 00345 00600 PRO_MAX_VAL 00346 00050 PRO_MIN_VAL 00347 00190 PRO_TRIG_VAL 00348 00002 PROREQUEST 00349 00002 PROCON 00350 00002 PROREADY 00351 00002 PROFIN 00352 00002 PROTEMP 00353 00002 PROLEVEL 00354 00002 PROJAM 00355 00000 PRO_FR 00356 01250 PROCON_TRIG 00357 01250 PRORDY_TRIG 00358 00190 PROFIN_TRIG 00359 00190 PROTMP_TRIG 00360 00190 PROLEV_TRIG 00361 00190 PROJAM_TRIG 00362 02500 PRO_MAX_EVAL 00363 00000 PRO_MIN_EVAL : : /* Parms for ps, laser, aircond autorelay added */ 00370 00002 RELAY_PS 00371 00002 RELAY_LASER 00372 00002 RELAY_AIRC 00373 00010 AUTO_FR : : /* Parms for temperatur sensors */ 00374 00000 TEMP_AIR 00375 00000 TEMP_CYL 00376 01200 TEMPSENS_MAX 00377 00080 TEMPSENS_MIN 00378 00010 TEMPCYL_FR 00379 00010 TEMPAIR_FR 00380 00000 TEMP_12V : : :********************************************************** :* Values for scannercontrol 6 * :********************************************************** : Focus parameters 00512 10000 FOCU_POS 00513 61785 FOCU_OFFSET 00514 10000 FOCU_ZERO_POS 00515 25000 FOCU_MAX_POS
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00516 20000 FOCU_MAX_DIST 00517 00300 FOCU_DIS_DEL 00518 00300 FOCU_EN_DEL 00519 00000 FOCU_REF_LLIM 00520 00040 FOCU_REF_DET 00521 00020 FOCU_REF_DV 00522 00000 FOCU_REF_MIN 00523 00000 FOCU_REF_NORM 00524 00000 FOCU_END_HLIM 00525 00000 FOCU_END_MAX 00526 00000 FOCU_END_NORM 00527 00180 FOCU_MIN_T 00528 00200 FOCU_SEEK_T 00529 00200 FOCU_MAX_T 00530 00300 FOCU_STOP_DEL 00531 02000 FOCU_HALL_HLIM 00532 00100 FOCU_HALL_LLIM 00533 00160 FOCU_MIN_VPP 00534 00000 FOCU_SECURE 00535 00005 FOCU_ROT_DET 00536 00060 FOCU_ROT_CNT 00537 00000 FOCU_ROT_MAX 00538 00000 FOCU_ROT_MIN 00539 00004 FOCU_ROT_C : : Focus film startpos in mm 00550 00050 FF_YPOS : Maximum guide position in cm 00551 00041 GUIDEMAX : : Iris parameters 00560 02000 IRIS_POS 00561 00000 IRIS_OFFSET 00562 02000 IRIS_ZERO_POS 00563 06300 IRIS_MAX_POS 00564 08000 IRIS_MAX_DIST 00565 00020 IRIS_TURN 00566 00300 IRIS_DIS_DEL 00567 00300 IRIS_EN_DEL 00568 00040 IRIS_ZERO_DET 00569 00020 IRIS_ZERO_DV 00570 00000 IRIS_ZERO_MAX 00571 00000 IRIS_ZERO_MIN 00572 02000 IRIS_HALL_HLIM 00573 00100 IRIS_HALL_LLIM 00574 00005 IRIS_ROT_DET 00575 00100 IRIS_ROT_CNT
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PAGE 2.7.13
00576 00004 IRIS_ROT_C 00577 00450 IRIS_MIN_T 00578 02000 IRIS_SEEK_T 00579 02000 IRIS_MAX_T 00580 00500 IRIS_STOP_DEL 00581 00020 IRIS_ZERO_C 00582 00320 IRIS_MIN_VPP 00583 00000 IRIS_ROT_MAX 00584 00000 IRIS_ROT_MIN 00585 00005 IRIS_EQ 00586 00030 IRIS_ZERO_LC 00587 00000 IRIS_ZERO_NH 00588 00001 IRIS_HICUR : :/* Filmmagazine position parameters XXXH */ 00600 00000 /* MAGA_POS Start or endsensor or unknown */ 00601 01200 /* MAGA_MOVE_LGT Turn length between positions */ 00602 03435 /* MAGA_SPREV Steps per revolution */ 00603 00350 /* MAGA_STEP_LGT Search length */ 00604 05000 /* MAGA_MAX_DIS Max. current disabled */ 00605 05000 /* MAGA_MAX_EN Max. current enabled */ 00606 00000 /* MAGA_MIN_EN Min. current enabled */ 00607 00300 /* MAGA_DIS_DEL Delay for disabling */ 00608 00300 /* MAGA_EN_DEL Delay for enabling */ 00609 03000 /* MAGA_HALL_HLIM Max. value */ 00610 00000 /* MAGA_HALL_LLIM Min. value */ 00611 01000 /* MAGA_SENS1_TRIG Trig value for sensor 1 */ 00612 01000 /* MAGA_SENS2_TRIG Trig value for sensor 2 */ 00613 05000 /* MAGA_ENC_DEL Delay for rotation control */ 00614 14000 /* MAGA_PULSE_T Pulse frq. timeperiod */ 00615 00250 /* MAGA_PULSE_L Pulse length in 20 us */ 00616 00010 /* MAGA_AFTRUN Steps after interrupt */ 00617 10000 /* MAGA_POSWAIT Delay at position */ : :/* Filter watch parameters */ 00660 00000 /* FILTER_FR Frequency for updating */ 00661 00500 /* FIL_TRIG_VAL Trig value for filter watch */ 00662 00002 /* FILTER Logic value (1 = ok, 0 = clogged) */ 00663 05000 /* FIL_HLIM High limit for signal */ 00664 00000 /* FIL_LLIM Low limit for signal */ : :/* Power off button */ 00672 00002 /* POWER_OFF Logic value */ 00673 00001 /* OFF_FR Monitor frequency */ 00674 00000 /* BOOT_MIN_EN Min. current enabled */ 00675 05000 /* BOOT_MAX_EN Max. current enabled */ 00676 01000 /* BOOT_EN_DEL Delay for enabling */
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00677 00000 /* PWR_MIN_EN Min. current enabled */ 00678 05000 /* PWR_MAX_EN Max. current enabled */ 00679 50000 /* PWR_EN_DEL Delay for enabling */ : :/* Air conditioning parameters */ 00700 00000 /* AIR_FR Frequency for updating */ 00701 00100 /* LIQ_TRIG_VAL Trig value for liquid sensor */ 00702 03000 /* HUM_HLIM High limit for humidity sensor */ 00703 00500 /* OFFL_TRIG_VAL Trig value for offline signal */ 00704 00002 /* LIQUID Logic value */ 00705 00002 /* HUMID Logic value */ 00706 00002 /* AIROFFL Logic value */ 00707 05000 /* AIR_HLIM High limit for signals */ 00708 00000 /* AIR_LLIM Low limit for signals */ 00709 00000 /* HUM_LLIM Low limit for humidity sensor */ : :/* Valve parameters */ 00710 00003 /* VALV_POS 0=free, 1=mani, 2=lock, 3=unkn. */ 00711 00010 /* VALV_TOPA Diff. limit for passing top/bottom */ 00712 00010 /* VALV_TOPB Diff. limit for passing top/bottom */ 00713 00040 /* VALV_EDGEA Diff. limit for detecting top/bottom */ 00714 00040 /* VALV_EDGEB Diff. limit for detecting top/bottom */ 00715 00300 /* VALV_DIS_DEL Delay when disabling motor */ 00716 00300 /* VALV_EN_DEL Delay when enabling motor */ 00717 05000 /* VALV_MAX_DIS Max. current when disabled */ 00718 05000 /* VALV_MAX_EN Max. current when enabled */ 00719 00000 /* VALV_MIN_EN Min. current when enabled */ 00720 00000 /* VALV_HLIMA Static pos. limits */ 00721 00000 /* VALV_LLIMA */ 00722 00000 /* VALV_HLIMB */ 00723 00000 /* VALV_LLIMB */ 00724 02000 /* VALV_HALL_HLIM Max. val. for valve sensors */ 00725 00050 /* VALV_HALL_LLIM Min. val. for valve sensors */ 00726 00010 /* VALV_LCONST Constant for pos.limit calc. */ 00727 02000 /* VALV_TOUT Value for time out */ 00728 02000 /* VALV_TOUT_T Time period for timer */ 00729 00060 /* VALV_MIN_VPP Min. peak-peak value for Hall-sensor */ 00730 00000 /* VALV_NORMA Normal value for hall A */ 00731 00000 /* VALV_NORMB Normal value for hall B */ 00732 00015 /* VALV_ECONST Constant for pos.limit calc. */ 00733 00002 /* VALV_SOFTCNT Error counter */ 00734 01000 /* FM_TRIG Filmmeter relay trig value */ : :/* Voltage limits and sec. relays */
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00736 00003 /* VOLT_FR Monitoring freq. */ 00737 00002 /* M24V_SC4 0=24V ok, 1=24V fail */ 00738 00002 /* M24V_SC5 0=24V ok, 1=24V fail */ 00739 00002 /* M24V_SC6 0=24V ok, 1=24V fail */ 00740 02500 /* A12V_POS_HLIM +12V upper limit */ 00741 02100 /* A12V_POS_LLIM +12V lower limit */ 00742 00300 /* A12V_NEG_HLIM -12V upper limit */ 00743 00080 /* A12V_NEG_LLIM -12V lower limit */ 00744 02927 /* M24V_HLIM 24V upper limit */ 00745 01945 /* M24V_LLIM 24V lower limit */ 00746 02300 /* D5V_HLIM 5V upper limit */ 00747 01900 /* D5V_LLIM 5V lower limit */ 00748 00600 /* R1V23_HLIM 1.23V upper limit */ 00749 00500 /* R1V23_LLIM 1.23V lower limit */ 00750 001FF /* MONIT_CMD Monitor command */ 00751 001FF /* DEBUG_CMD Debug command */ 00752 00005 /* SEC_RELAY_SC4 Relay status : */ 00753 00005 /* SEC_RELAY_SC5 0=ok, 1=fail, 2=illegal, */ 00754 00005 /* SEC_RELAY_SC6 3=fail on prev. module */ 00755 00002 /* M24V_SC7 0=24V ok, 1=24V fail */ 00756 00005 /* SEC_RELAY_SC7 */ 00757 00100 /* SAFETY_TRIG Trig value */ 00758 00005 /* SAFETY_SIG 1 = on, 0 = off */ : :/**********************************************************/ :/* Values for scannercontrol 5 */ :/**********************************************************/ :/* Ultra sound sensor values */ 00760 00000 /* US7_MONIT Start monit then 1, else 0 and stop */ 00761 00001 /* US7_MON_FR Monitorering frequency */ 00763 00600 /* US7_TRIG_VALUE Value for seeing the film */ 00764 00070 /* US7_MAX_COUNT Max. time for turning cassette */ 00765 00000 /* US7_UNLOAD_FLAG Max. time for turning cassette */ : 00000 33333 /* Control parameter for security */ 00767 44444 /* Control parameter for security */ :
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2.7.3. PGM Parameter List

:/**********************************************************/ :/* REFERENCE PARAMETERS FOR THE PGM */ :/*--------------------------------------------------------*/ :/* Version : 1.07 of 10.11.95 */ :/* Author : Morten S. Christiansen, Purup Prepress A/S */ :/* 10.11.95 Copied from 6.00. */ :/* Param. 31 removed. */ :/**********************************************************/ : 00000 33333 /* Control parameter for security */ : :/* Laser parameters */ 00001 00000 LASER_MON_VAL 00002 04095 LASER_MAX 00003 01570 AR_LASER_MIN : : :/* Spindel parameters */ 00010 00000 COUNT_H 00011 00000 COUNT_M 00012 00000 COUNT_L 00013 00580 SPD_MES_TIME 00014 00004 SPD_MIN_SPEED 00015 00130 SPD_MAX_SPEED 00016 00080 MAX_LIN_SPEED 00017 65535 SPDL_ENC_HLIM 00018 00000 SPDL_ENC_LLIM 00019 12500 LOADPOINT 00020 00008 LIN_RAMP 00021 00000 RAMP_TST_LGT 00022 00000 IR_WIDTH 00023 07200 IRW_MIN 00024 08800 IRW_MAX 00025 00000 IRTOMY_LGT 00026 02500 IRMY_MIN 00027 03500 IRMY_MAX 00028 00000 ZERO_HYST 00029 00010 ZHYST_MAX : :/* DC-servo parameters */ 00030 00000 DC_SERVO 00032 00000 SINGLESTEP 00033 00000 HALLENC : :/* Sensor trig value parameters */
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00040 01000 MY_TRIG_VAL 00041 00100 IR_TRIG_VAL 00042 01000 EM_TRIG_VAL 00043 01000 GUIDE_TRIG_VAL : :/* Spinner parameters */ 00050 01000 OFFSET_VALUE 00051 65535 SPIN_ENC_HLIM 00052 00000 SPIN_ENC_LLIM 00053 00200 SPIN_START_12 00054 00200 SPIN_START_24 00055 00100 VAR_SPIN_12 00056 00100 VAR_SPIN_24 00057 00000 SP_SPEED_F 00058 01350 SPEED_DELAY 00059 00240 SPIN_SHUT_DEL 00060 00020 SPIN_SHUT_TIME : : :/* Debug and monitor control parameters */ 00080 00000 MONIT_CMD 00081 00000 DEBUG_CMD : : : /* Parameters for exp. ctrl. */ 00100 00000 EXT_RW_ENABLE 00101 00000 EXP_POS_H 00102 00000 EXP_POS_L 00103 00000 EXP_RESOL 00104 00000 OB_RE_EXP 00105 00000 EXP_START_LINE 00106 00000 MAX_LINES_LOW 00107 00000 MAX_LINES_HIGH 00108 00000 EXPOSED LINES 00109 00000 RS_ENABLED 00110 00000 GUIDESENSING : :/* Parameters laser ftest */ 00125 00300 MIN_FILM_CARR /* Optimizing param, used on PC */ : :/* Control parameters */ 00000 33333 /* First control parameter */ 00149 44444 /* Last control parameter */
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PURUP IMAGEMAKER MAGNUM ADJUSTMENTS
PAGE 2.8.1
2.8. Adjustments
2.8.1. Formats and References
On the Magnum, Magnum/RS and Mercury it is possible to expose outside the film edge (for printing plates). This means that the zero point for the exposure (first dot) will always be placed outside the film.
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Unit Max exposure format Max physical film format User format
MAGNUM
MAGNUM/RS
MERCURY
825*1206mm 820*1200mm
825*856mm
625*726mm
820*1000mm 815*1194mm 815*844mm
620*762mm 615*756mm
These formats are based on a margin of 6mm in the length of the film and 5mm in the width. On the first Magnums with software ver. 6.00 these margins are 4mm and 2mm, respectively. When later software versions (6.01 6.02) are loaded on these Magnums, the margins will not be changed automatically, however, it is possible to change them in the configuration (Change Loader Constants point 7 and 8). The margins can have values from 2 to 5mm (horizontally/ xdirection) and 4 to 6 mm (vertically / y-direction). The connection between margins and format is:
Margin Max exp format SPT Montage format SPT Max exp. height SPT Max exp. width 2*4mm 822*1204mm 820*1200mm 818mm 1196mm 5*6mm 825*1206mm 820*1200mm 815mm 1194mm
Normally the margins should not be changed, and if they are, a readjustment from scratch must be made, and the changed margins in the adjustment procedures must be taken into account. References HSOS: OFC: VSOS: LEP: Horizontal Start of Scan, defined by OF Offset Counter, value keyed into the configuration program Vertical Start Of Scan, defined by LEP Left End Point, value keyed into configuration program
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PSOS: UBC: DTFS: LF: REP: HEOS:
Physical Start of Scan, where the beam is cut by the bottom belt roller Unload Before Cut, value keyed into configuration program Distance To Film Sensor, value keyed into configuration program Load Factor, value keyed into configuration program Right End Point (Vertical end of scan) Horizontal End Of Scan
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2.8.2. Film Loader Adjustment
2.8.2.1. Adjust DTFS
(item 2 in Change loader constants) This describes the load distance from film load start until the film passes the IR sensor in the cylinder.

Make a 250-mm Dump film Adjust DTFS until the length fits (increase DTFS if the film is too long).
2.8.2.2. Adjust LF
(item 1 in Change loader constants) This describes the load factor for controlling the amount of film to be loaded into the cylinder.

Make a maximum length Dump Film (eg. 1200mm) Adjust LF until the length fits (increase LF if the film is too long). Change LF with 1 for each 1.5 mm length error.
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2.8.2.3. Adjust LD
(item 9 in Film data under Define film type) The load length depends of the film thickness (a 0.11mm film/plate might load longer than a 0.1mm). The Magnum is tested with a 0.1mm thick film, and the machine dependant parameters are adjusted accordingly. The LD can be set to values from 970 to 1030 where 1000 means that the film type should not be adjusted (all 0.1mm thick film should therefore have an LD of 1000).

Make a 1000mm Dump film (with an LD value of 1000) Key in the length measured as the new LD for this film type.
2.8.2.4. Adjust UBC
(item 6 in Change loader constants) This describes the length of film to be reversed into the magazine prior to cutting the film after exposure (Purup no waste concept).

Run an offset film from the service program, with Boundary marks TopLeft. Adjust UBC until the film is cut in the centre corner mark (increase UBC if more film is to be cut off - change UBC with 1 for each 0.5mm length error). Note that the left part cannot
be seen if the machine has a special guide for punch.
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The boundary marks indicate the three areas explained on page 2.8.1.
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PAGE 2.8.7
2.8.3. Exposure and Film Format Adjustment
2.8.3.1. Coarse Adjustment of HSOS/OFC
Run an offset film from the service program, with Initial Offset marks. The film will contain up to 4 lines marked with 2 measurements: One in mm and a direct reference to OFC. You turn the film to read the numbers, and you should measure Xio from the bottom edge of the film. To this figure you add 3mm (1/2 margin) and calculate a new OFC by adding (Xio + 3)*50 to the OFC reference of the line. (new)OFC = OFC (line reference) + 50 * (Xio + 3) Example:
(new)OFC = 60000 + 50 ( 281 + 3) (new)OFC = 60000 + 14200 (new)OFC = 74200 NOTE: 1 unit in OFC equals 20 => 50 units = 1mm Key the new OFC (5/10/20) into the configuration program in CHANGE SPINNER CONSTANTS.
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2.8.3.2. Find PSOS and Fine Adjust HSOS/OFC
Run an offset film from the service program, with Offset adjust marks - top and Dont unload before cut. This film will expose a 5-mm wide line in the area where the laser beam is cut by the bottom roller. Adjust OFC until approx. 2 mm of the line is visible before the laser beam is cut (decrease OFC if you want more of the line on the film).
Key the new OFC (5/10/20) into the configuration program in CHANGE SPINNER CONSTANTS. Use the point 6 Automatic offset adjust to calculate the values in 6.4m and 8m. This means that point 2 and 3 in Change spinner constants should not be set.
2.8.3.3. Adjust LEP
The LEP describes the left end point of the carriage, also called the Vertical Start Of Scan (VSOS). The left end point is normally used for adjusting the distance from the register system to the image start. Make an offset film from the service program with Boundary marks - TopLeft. Adjust LEP (point 1 in Change Carriage Constants) until the centre mark is at the edge of the film. The left end point (LEP) is entered in 1/1000 mm () and it is default set to 6000. The minimum LEP value is 0.
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Note: On systems with register system the special guide will cover this part of the film. In that case use the Boundary marks - Top Right (BTR). When LEP is adjusted, a new value for Right End Point (point 2 in Change Carriage Constants) might have to be calculated, in order to obtain full exposure format. REP is entered in 1/10 mm and default is 8300 (for Magnum). The minimum value for REP=825mm + LEP + margin If you set REP to eg. 8350, you will have no problem regarding this.
Note:
In the figure above the measurements A and B are included as additional information.
A:
This measurement represents the adjustment of the film magazine roller. It can be changed by means of the washer kit no. 4000112.
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B:
This measurement represents the UBC controlling the length of film to be reversed into the magazine prior to cutting the film.
2.8.3.4. Reestablishing Adjustment After Repair (With Reg. Units)
After repair (eg. exchange of spinner) the offset (OFC) must be set to fit the previous setup of the register position. To do this two methods can be used: NOTE: Do not change the figures for the register unit positions in the configuration program.
1.a. Run an offset film with the controlling register unit (ref 1) selected, and position marks. Select 1270 dpi and as few register units as possible, e.g. 3. b. Place this film on top of the reference film made during installation of the register units (included with the Magnum from PP production). Adjust OFC until the centre line fits to the centre of the register hole of the reference pin, and the two films are exactly the same.
c.
d.
If necessary, you could first make a coarce adjustment of HSOS/OFC.
If a reference film is not present, the following method can be used to adjsut the offset. 2.a Run an offset film (from the Service program) with the controlling register unit selected, and Position marks. Select 1270 dpi and as few register units as possible, e.g. 3.
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b.
Repeat so that you have two pieces of film that are exactly the same. Place one film on top of the other on the Pin register bar, one emulsion up and one emulsion down. Measure the difference between the reference lines for the controling register (ref 1) on the two films. To have an exact measurement, measure from the inside of the line An example is shown in figure 2.8.3.1 where the distance between the lines, 4.1, is 21 mm.
c.
Figure 2.8.3.1 d. Adjust offset to the value wanted. In the example offset is
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changed with half of 21 mm multiplied by 50 as offset is adjusted in units of 20m (10.5mm x 50 = 525). e. Repeat step 2.a and check that the position marks are now on top of each other as illustrated below.
2.8.3.5. Reestablising Adjustment Ater Repair (Without Register Units)
Reuse as much of the existing adjustments as possible, but in principle you should proceed as when adjusting from scratch.

Coarse adjustment of HSOS/OFC Find PSOS and fine adjust HSOS/OFC Adjust UBC Adjust DTFS Adjust LF Adjust LEP/VSOS
2.8.3.6. Readjustment Due to Erroneous Adjustment
If it turns out that a machine has not been adjusted correctly (load length wrong, or the job is placed obliquely on the film), you should try to correct the adjustment without moving the customers job in relation to the register position (if the customer has no register there is no problem). The vertical position of the job in relation to the film, can be adjusted by changing LEP. The horizontal position of the job can be adjusted by changing UBC and DTFS. Do not change OFC as you would also have to correct all horizontal values of the register unit positions which would cause problems to the customer.
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Errors in the load length can be corrected by changing UBC, DTFS, and LF.
2.8.3.7. Adjustment of Drum Scaling
1.
Expose two test films 1201 in 2540 dpi on a fully adjusted MAGNUM, i.e. density, focus, and mechanical/optical adjustments have been completed. Tape the first film at each side of the film to a viewer (typically switched off), or to a white table which will provide sufficient light for this control method. See the figure below
2.
On top of the first film, place the second test film 1201 with the emulsion side downwards, turned 90 degrees in order to compare the horizontal scanning on the first (bottom) film with the vertical scanning on the second (top) film. See the following figure:
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3.
Line up the test film with reference in point A and verify the deviation in point B. This deviation will indicate a scaling error that can be either positive or negative, and you can identify the films by checking the scan lines. The jagged scan line belongs to the bottom film and the straight scan line belongs to the top test film. Place an X 75 magnifying glass on the 820 mm line, and key in the difference between the two lines as MEASURED and WANTED values in PIM machine configuration, e.g.: The dialogue box is placed in upper left corner on test film 1201. Measured = 82004 Wanted = 82000
4.
Note:
5.
Make a restart of the PS-Link, a LOG OUT/IN via the SPT program, expose another set of 1201 test films and continue the above procedure until the lines overlap.
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2.8.4. Focus Adjustment
Adjustment of the focus system is done upon changing vital parts in the ImageMaker such as laser, fiber, optical housing, or spinner. 1. Enter the Service program and select Control, Focus, Focus film Enter magazine number Choose a suitable laser power setting and Yes to Function Test.
2. 3.
4.
Evaluate the focus film and measure the focus distance from start of scan to the focal point on the exposed area as shown on fig. 2.8.4.1. If you do not obtain a film as shown, with two dark sides and a light stripe in the middle, you will have to run a new film with a changed laser power.
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Figure 2.8.4.1 5. Use the Control, Focus, Set focus program to enter the measured distance.
6.
In the position of focus dialog box that comes up, the automatic calculated new focus position is shown.
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7.
Select yes to position focus. The new focus position is now automatically set. Remember to make a new backup of the configuration files.
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PURUP IMAGEMAKER MAGNUM MECHANICS
PAGE 3.1.1
3.
Mechanics
The primary purpose of the drum is to position and hold the exposure media on the internal drum surface. Furthermore, the drum is the mounting surface for various mechanical and electrical components, with the following parts:
Drum
3.1. Drum
Film loader
Linear system
Vacuum system
Register system
Optical system
Spinner system
The drum is shaped so that 270 degrees of the internal diameter are used for exposure. Furthermore, it incorporates machined grooves for vacuum system and installation of Head and Tail register system. The drum also holds the Linear system, with the Spinner system and Optical system mounted on a carriage, driven by a lead screw. Tolerance relations in the mechanical build up of the drum:
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Figure 3.1.1
3.1.1. Pre-Installation of Register System
Prerequisites: Purup ImageMaker Test Film Diskette (included in the service manual) Order form, specifying the individual configured register system.
Procedure: 1. Install the Test Film Diskette on a MacIntosh, select PIM TEST film level 2" and PS-Files. See figure 3.1.1.1.
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PAGE 3.1.3
Figure 3.1.1.1
2.
Open the MagnumRegister.PS in BBEdit and edit the section describing the register unit position. See figure 3.1.1.2.
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Figure 3.1.1.2
3.
Highlight all the present coordinates for the registers and enter each of the register coordinates for the register system that you are about to install. Note: Remember that the units are in mm and use a normal dot . to indicate decimals. 1st register unit position 150.5 mm, equal to 150500 microns 2nd register unit position 450.5 mm, equal to 450500 microns 3rd register unit position 750.5 mm, equal to 750500 microns
Ex.
4.
Save the file after editing, and give it a name that relates to this customers register system for later use. Open StandardPageTool, create a new montage, select magazine film roll, import the frame file, and expose the job. Inspect the exposed job for later use, when installing the register system. PURUP PREPRESS A/S
5.
6.
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PAGE 3.1.5
3.1.2. Installation of Register System (Head Register)
Note:
Before installing the register system, it is very wise to run a test job that will indicate the position of the registers. This test job is included in the Test Film Diskette from Purup. Follow the procedure, Pre-installation of Register System, chapter 3.1.1.
1.
Adjust the machine offset, UBC, etc. Please refer to the Adjustment chapter 2.8. Sort the register units, identify which units have reference pins and which units have guide pins, and note the position of the units in the drum in accordance with the order specification. Dismount the film guide in the optical housing side of the carriage, and mount the cable 323 as shortcut for the dismounted jam sensors. Run the carriage approx. 400 mm to the right. Place the register system frame job, see chapter 3.1.1., in the drum so that 0" on the ruler is 5mm from the edge of the groove edge (see fig. 3.1.2.1) and the horizontal edge along the groove edge. Fix it by activating the vacuum system so that it is aligned to the edge of the exposure area start point. See figure 3.1.2.2
2.
3.
4. 5.
Fig. 3.1.2.1
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Figure 3.1.2.2
6.
Install all the registers so that they match the position of the silhouette on the register frame job, mounted in the drum. Note: Make sure that all the units are mounted in the correct position with the correct orientation and size.
7.
Connect all wirings for the register units. Note: The cable connector position is not equal to the logical position.
8.
Configure the register system, see chapter 2.3.1.4, Define Register Types. Note: On some machines the physical position of the register units does not match the logical position, given in the register configuration program. In this case, it will be necessary to verify the real position of each register unit by activating the register units
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PAGE 3.1.7
one by one, and make a function test of each individual register unit or refer to the label on the wire. Typically, the real position of the register units could be like the system in below figure:
Figure 3.1.2.3 9. Check the punched film on the system register bar, and adjust the units until the system is correct. Mount the spacers 4x25 mm (yellow). Cut the first and the last spacer in the correct length (are delivered oversize). Mount spacer 5x15 mm (red), mark and cut holes for M4 screws (1 or 2 holes per screw). Mount the register guide with M4 screws and discs in the long holes where possible for the register units. There should always be at least one fixing screw before the first register unit. If there is no long hole that fits, cut an M4 thread hole to ensure that the film is guided correctly into the drum. Check with a piece of film that the film slides easily through the entire register system and run a film to check that the hole distance still fits.
10.
11.
12.
13.
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14.
Verify that all the combinations ordered by customer are selectable from StandardPageTool and in correct position on the film output. In order to secure the accuracy of job position in relation to the register unit, the punch position value in the Configuration program for the controlling register (ref. 1) should be adjusted. Please follow the procedure below. Run an offset film (from the Service program) with the controlling register unit selected, and Position marks. Select 1270 dpi and as few register units as possible, e.g. 3.
15.
16.
Repeat so that you have two pieces of film that are exactly the same. 17. Place one film on top of the other on the Pin register bar, one emulsion up and one emulsion down. Measure the difference between the reference lines for the controling register (ref 1) on the two films. To have an exact measurement, measure from the inside of the line An example is shown in figure 3.1.2.4. where the distance between the lines, 4.1, is 21 mm.
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Figure 3.1.2.4
To determine whether the punch position value should be increased or decreased, check the film with emulsion up (right read), see figure 3.1.2.4, and determine whether the position mark is to the right (+) or to the left (-) of the physical hole in the film. In the example the mark is to the left which means that the position value should be decreased. 18. In the example the distance between the marks is 21 mm which means that the punch position value in the configuration program for ref. 1 should be decreased by 10.5 mm (10,500 micron) which is half of the measured distance. If the punch position value is e.g 514500, the new value will be: 514500-10500 = 504000. Enter the new value in the configuration program, please refer to chapter 2.3.1.4.1. 19. Repeat step 16 and check that the position marks are now on top of each other as illustrated below.
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20.
If your PIM has scaling in the drum, the information in PST under exposed area will not be the same as in the console software. Therefore, restart the SPT software with a Restart all to be sure that the PS-Link has read the information from the PIM correctly. Save the film as it can be helpful for later adjustment of offset, e.g. in connection with a change of spinner.
21.
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3.1.3. Installation of Special Register System (Head, Tail, or Side)
Mounting of extra cables as described below is only necessary for machines with a serial number below approx. 100. On newer machines the cables are placed in the cable duct behind the drum.
3.1.3.1. Mounting of Extra Cables
If there are more than two register units, extra cables have to be used. Two extra drivers for the register units are possible on SCM 4 and one on SCM 5. On SCM 4 the motor cable 410 should be connected to J10 on the SCM4 connector board, the Hall element cable 412/5-R12 should be connected to J12. The mounted connector is only a protection connector, therefore you should dismount it and mount the white wire in SCM 4 J12 no 13, the brown wire in 14 and the green wire in 15.
Green White

15 16

13 14 11 12 9 10 7 8 5 6 3 4 1 2

Brown The register driver is number 12. On SCM 5 connect the motor cable 505/2 to J5, white in pin 7 and brown in pin 8. Connect the Hall cable 503/2 to J3, white to pin 10, brown to pin 11 and green to pin 12. The register driver is no. 13.
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If there are more than 9 register units, SCM7 has to be installed. On SCM 7 there are 5 extra drivers. The cable numbers are Motor 706 and Hall 12. Set SCM7 active in the Module Configuration. See chapter 2.3.1.5
3.1.3.2. Choosing The Register Driver for Double Units
The different drivers have different effect: Register no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Module SCM4 SCM4 SCM4 SCM4 SCM5 SCM5 SCM5 SCM7 SCM7 SCM7 SCM7 SCM4 SCM5 SCM7 Motor driver C2 (weakest) C1 (weakest) B (second strongest) A (strongest) C2 C1 B C2 C1 B A B B B
Use type A or B for double units. All types can be used for normal units.
3.1.3.3. Tail-Punch Units
When mounting a tail-punch system, it can be an advantage to start with the tail units in order to make the milling of the film guide fit over the register units and simultaneously fit the 0 Exposure. In order to place precisely the reference units in the head and tail end, use a magnet base and a 0.01 mm finger dial indicator. 1. Dismount the Allen screws holding the carriage in the spindle nut so that you can move the carriage by hand.
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2.
Place the magnet base on the beam screen guide at the centre of the carriage and set the finger dial to 0 on the reference register unit matrix as closely to the drum wall as possible (the unit that fits to the 0 Exposure). Move the carriage by hand to the register unit at the opposite end and adjust the unit until the units at both ends fit within 0.02 mm. It may be necessary to check the 0 point several times by moving the carriage back and check that there is still 0 on the matrix with which you started. When you are mounting a tail punch you should also mount hoses and tubes for the register waste from the tail end. Move the angular connection piece in the head end to the tail end and mount the T-tube in the head end. Connect to two tubes with the hose.
3.
4.
5.
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PURUP IMAGEMAKER MAGNUM LINEAR SYSTEM
PAGE 3.2.1
3.2. Linear System
The purpose of the Linear system is to hold and move the spinner and optical housing in a unique centre line of the drum.
3.2.1. Spinner
3.2.1.1. Demounting the Spinner
1.
Open the lower left door, turn the service key, open the upper left door, remove the protection cap for the optical housing, unscrew the optical fibre, and secure the fibre with the rubber protection cap. If you do not follow point 1, you will risk that laser light is emitted directly out of the optical housing when the spinner unit is removed.
WARNING:
2.
Load the Service program, move the carriage 800 mm to the right, and turn the service key to the ON position. Open the right door and remove the support pin for the carriage flex cable. Open the carriage flex cable to expose the cables. Note: This is only necessary if you are working with a pigtailed spinner unit.
3.
4.
5.
Undo the spinner connector at the spinner driver and at the PGM. Free the cables coming from the spinner driver and the PGM leading to the spinner unit. (In order to access the PGM board, remove the upper front plate and tilt down the electronic module plate). Demount the connectors for the jam sensors and the IR sensor 3 on the rear film guide. Remove the rear film guide by loosening the two fixed screws on the inner plate of the film guide.
6.
7.
8.
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9.
Having the spinner cables fully dismounted, loosen the two fixed screws for the steel strap tensioners at the front of the carriage unit, holding the spinner unit. Note: The metal straps are mounted in two ends. Loosen the screws at the front with the special tension bolts and DO NOT loosen the steel straps at the base of the spinner housing. Some machines have liners between the spinner unit housing and the carriage rest points, and the position of those liners MUST NOT BE LOST as this will have a negative influence on the geometric accuracy of the output.
WARNING:
10.
Gently pull the spinner backwards until you can remove it. Note: The spinner housing surface and the spinner mirror are very delicate. Damage will affect alignment and exposure quality. No credit on return will be given if the spinner housing is damaged or if the mirror is scratched or damaged.
3.2.1.2. Mounting the Spinner
1.
Gently insert the spinner unit on the carriage rest points and support the steel straps so that they easily surround the spinner unit. Note: Supporting the steel strap tensioners in order to slide the spinner unit in may be necessary.
2.
Align the spinner unit so that the wire coming out of the encoder cap is in 12 oclock position and the motor cable is in 3 oclock position. Note: The spinner unit should be allowed to engage with the stop screw mounted in the carriage base.
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WARNING:
Some machines have liners between the spinner unit housing and the carriage rest points, and the position of these liners must be as they were during removal of the spinner unit, as this will have a negative influence on the geometric accuracy of the output.
3.
Fix the spinner unit in this position by tightening the steel strap suspension screws. The torque on the steel strap suspension screws is vital to the geometric accuracy of the machine and you must use the torque wrench in the alignment kit set to 0.8 Nm. If you do not have a torque wrench make sure that the gap between the top and the base of the steel strap tensioners is the same for both steel straps.
WARNING:
4.
Mount the rear film guide and make sure that it gives enough free space for the film to pass between the drum surface and the guide. Redo the wiring. Redo the cabinet plates and close the doors. Use the FIND AND EJECT command in STATUS to bring the carriage to the home position. Mount the fibre on the optical housing. Do a focus film/adjustment, and density film/ adjustment. Run test films to verify the Grid Fit on the test film (#1201). If you have to adjust the offset, the appropriate procedure should be chosen (with/without register unit), see chapter 2.8.3. Finish the operation.
5. 6. 7.
8. 9.
10.
11.
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3.2.2. Optical Housing
See engineering drawing 5803168 in chapter 10.4
3.2.2.1. Demounting The Optical Housing
1.
Open the lower left door, turn the service key, open the upper left door, remove the protection cap for the optical housing, and unscrew the optic fibre and secure the fibre with the rubber protection cap. If you service a machine without head register, remove the front film guide by loosening the two fixed screws for the film guide centre plate, and unplug the connector for the jam sensors. If not, go to point 3. Loosen the four fixed screws for the IRIS and FOCUS motor plate, on the optical housing, and pull out/away the motor plate. Note: Do not use force while pulle off the Iris and the Focus motor plate. The Iris and focus motor should turn as the worm gears release. If you force, you risk that the Iris and the Focus system is driven to an extreme position and cannot be recovered by the function test.
2.
3.
4.
Having the optical housing fully dismounted, loosen the two fixed screws for the steel strap tensioners at the front of the carriage unit, holding the optical housing. Note: The metal straps are mounted in two ends. Loosen the screws at the front with the special tension bolts and DO NOT loosen the steel straps at the base of the carriage.
5.
Gently pull the optical housing backwards until you can take it out. Note: The fix surfaces and the focus lens, of the optical housing are very delicate. Damage will affect alignment and exposure quality.
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PAGE 3.2.5
No credit on return will be given if the optical housing is damaged or the focus lens is scratched or damaged
3.2.2.2. Mounting The Optical Housing
1.
Gently insert the optical housing on the carriage rest points and support the steel straps so that they easily surround the optical housing. Note: Supporting the steel strap tensioners in order to slide the optical housing in may be necessary.
2.
Before fixing the optical housing steel straps, check that: a) The optical housing should be allowed to engage with the stop screw mounted in the carriage base. Rotate the optical housing until it is possible to mount the IRIS and FOCUS motor plate.
b)
3.
Fix the optical housing in this position by tightening the steel strap suspension screws. The torque on the steel strap suspension screws is vital to the geometric accuracy of the machine and you must use the torque wrench in the alignment kit set to 0.8 Nm. If you do not have a torque wrench make sure that the gap between the top and the base of the steel strap tensioners is the same for both steel straps.
WARNING:
4.
Mount the IRIS and FOCUS motor plate. Note: Do not use force while mounting the IRIS and focus motor plate. The IRIS and focus motor should turn as the worm gears engage. If you force, you risk that the IRIS and the focus system are driven to an extreme position that cannot be recovered by the function test.
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REV. E
5.
Mount the film guides (if mounted) and make sure that they give sufficient free space for the film to pass between the drum surface and the guides. Redo the wiring, cabinet plates and close the doors. Use the FIND AND EJECT command in STATUS to bring the carriage to the home position. Mount the fibre on the optical housing. Do a function test of Iris and Focus system. Run test films to verify the Grid Fit on the test film (#201), and if the customer has a specified distance from a register system, this has to be taken into consideration. See chapter 2.5 for evaluation of test films.
6. 7.
8. 9. 10.
3.2.2.3. PSD Adjustment of The Optical Housing
Warning: This procedure may only be carried out by service staff who are trained, and have routine in this service routine. The PSD adjustment serves the very vital parts of the ImageMaker Magnum, and it is strictly for authorized personnel only. Finally, this calibration can only be done with special service tools. 1. 2. Remove the spinner, see item 3.2.1.1. Remove the anti flare guides from the middle of the carriage. Insert the dummy spinner and mount the PSD arm. Note: The dummy spinner must be mounted with the short axle pointing against the optical housing and held loosely while mounting the PSD arm.
3.
4.
Tighten the steel strap suspension screws, and notice that the PSD arm can swing the 270 inside the drum. The torque on the steel strap suspension screws is vital to the geometric accuracy of PURUP PREPRESS A/S
WARNING:
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PAGE 3.2.7
the machine, also when you do adjustments, and you must use the torque wrench in the alignment kit set to 0.8 Nm. If you do not have a torque wrench make sure that the gap between the top and the base of the steel strap tensioners is the same for both steel straps. 5. Insert the PSD probe into the PSD arm, connect the PSD probe cable to the PSD box, and set up the test equipment.
6.
Mount the DUMMY PSD probe into the PSD arm, set the laser ON, and set the laser power to approx. 2500. Set the Iris to 4800 and the focus to 15000. If you look carefully into the DUMMY PSD probe you should be able to see the laser beam spot on the probe paper. The probe paper is IR sensitive so IR laser light should also be visible.
WARNING:
Never look into the laser light without eye protection!
7.
Adjust on the PSD mirror screws until the laser beam spot is in the centre of the DUMMY PSD probe paper crosshairs.
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REV. E
Note:
Always adjust the bottom screw first, with the rear screw loose in order not to damage the PSD mirror.
Main Mirror PSD Arm Laser Beam Spot
Probe Position PARALELL
Dummy PSD Crosshairs Rear Screw PSD Mirror
Bottom screw Probe Position ANGULAR
8.
Fix the PSD probe fully out, measuring ANGULAR Beam Displacement and set up a suitable laser power via the Service Program. The PSD box power meter should read between 6 and 8. Adjust the X & Y offset potmeters on the PSD box until you can see the laser beam spot on the oscilloscope.
9.
Swing the PSD arm and observe that you have a corresponding movement on the Oscilloscope. If not check that the scope is set up correctly.
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PAGE 3.2.9
10.
Adjust on the ANGULAR adjustment screws on the optical housing in order to minimise the circular movement on the scope. The best way is to observe the centre of the PSD circle, and adjust until the beam spot hits the circle centre.
11.
Adjust on the ANGULAR adjustment screws until you are within 20 (20mV/Div).
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Angular Adjustment Screws (3)
Fibre Attachment

Paralell Adjustment Screws (4)
is very tight, it can be solved by losing the opposite screw.
12.
Fix the PSD probe fully in, measuring PARALELL Beam Displacement , and adjust the X & Y offset potmeters on the PSD box until you can see the laser beam spot on the oscilloscope. It may be necessary to change the sensitivity of the scope to 100mV/Div. Swing the PSD arm and observe that you have a corresponding movement on the Oscilloscope. Adjust on the PARALELL adjustment screws on the optical housing in order to minimise the circular movement on the scope. The best way is to observe the centre of the PSD circle, and adjust until the beam spot hits the circle centre.
13.
14.
15.
Adjust on the PARALELL adjustment screws until you are within 20 (20mV/Div). Fix the PSD probe fully out, measuring ANGULAR Beam Displacement , and adjust the X & Y offset potmeters on the PSD box until you can see the laser beam spot on the oscilloscope.
16.
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PAGE 3.2.11
17.
Adjust on the ANGULAR until you are within 10 (10mV/Div). The specs for the optical adjustment is 10 for ANGULAR and 20 for PARALELL, but it is usually easy to obtain an even better result, so always try to adjust to the optimum result.
Note:
18.
Remove all tools, mount the spinner, redo the wiring, and close the cabinet. Do a focus film/adjustment, and density film/ adjustment. Expose test films #201, #220, and #203, see chapter 2.5. Finish the operation.
19.
20. 21.
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3.2.3. Calibrating the Linear System to the Drum
WARNING: This procedure may only be carried out by service staff who are trained and have routine in this service routine. The linear calibration serves the very vital parts of the ImageMaker Magnum, and it is strictly for authorized personnel only. Finally, this service routine can only be done with special tools. 1. 2. Remove the spinner, see item 3.2.1.1. Remove the anti flare guides from the middle of the carriage. Insert the dummy spinner and mount the probe arm. Tighten the steel strap suspension screws, and notice that the probe arm can swing the 270 inside the drum. The torque on the steel strap suspension screws is vital to the geometric accuracy of the machine, also when you do adjustments, and you must use the torque wrench in the alignment kit set to 1.2 Nm. If you do not have a torque wrench make sure that the gap between the top and the base of the steel strap tensioners is the same for both steel straps.
3. 4.
WARNING:
5.
Mount the TESA Tronic probe into the probe arm, connect the metre and set the measuring scale to 100. Create an image of what the alignment looks like, so far.
6.
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PAGE 3.2.13
Principles
7.
Measure observation plane A by taking measurements at both the top and bottom of the drum. In the example below, the figures in plane A are -20 (UP) and +10 (DOWN), meaning that the difference is 30 between UP and DOWN positions, and this is just on the limit for approval. In such a case optimising this measurement would be natural. Note: The smaller reading between UP/DOWN positions, means higher exposure accuracy.

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REV. E
8.
Measure out observation plane B by taking measurements at the FRONT and the REAR of the drum. In the example below the figures in plane B is -13 (REAR) and +12 (FRONT), meaning that the difference is 27 between REAR and FRONT positions, and this is close to the limit for approval. In such a case optimising this measurement would be natural. Note: The smaller reading between FRONT/REAR positions, means higher exposure accuracy.
9.
Loosen the 4 fixed screws for the Linear System with the big torque wrench and the 8mm Allen HEX Socket Bit.
10.
Optimise the measurements for planes A and B in Left and Right side of the drum.
General: The general idea is to narrow down the tolerances in both plane A and plane B, in both LEFT and RIGHT side of the drum. Typical figures are 15.
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PAGE 3.2.15

11.
Fix the Linear System and observe that the measurements are ok. Note: Remember to use the torque wrench for this operation! The torque must be preset to 72 Nm.
12.
Remove all tools, and remount the spinner, see item 3.2.1.2
3.2.4. Spindle 3.2.4.1. Dismounting The Spindle 1. 2. 3. Move the carriage approx. 150 mm to the right. Remove the left and right bellows covering the spindle. Loosen the clutch between the spindle and the spindle motor ( 2 Allen keys through the hole in the bearing housing). Remove the 4 screws in the left spindle bearing housing. Push carefully the carriage to the right. The bearing in the right end of the spindle is fixed in the right bearing
4. 5.
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REV. E
housing with a rubber O-ring. This bearing is pushed out of the bearing when you puch the carriage to the right. 6. When the spindle is out of the bearing housing in the left side, remove the screw fixing the carriage to the spindle nut. Pull the spindle to the left until the spindle nut is clear of the carriage, tip the spindle clear of the housing, and pull it to the left. Be careful as the bearing in the right side must pass through the housing and later the carriage without touching (the spindle can easily be damaged if you are not careful).
3.2.4.2. Mounting The Spindle
1. 2.
Move the spindle nut to the center of the spindle. Push the spindle from the left under the carriage and through the bearing housing in the right side (be careful that the spindle does not touch the carriage or housing). Run the carriage over the spindle nut and fix the nut to the carriage (1 Allen screw). Push carefully the carriage to the left untill the bearings in the left side of the spindle are in position in the left bearing housing. Screw the 4 screws diaginally fixing the spindle in the left bearing housing. Fix the clutch to the spindle with the 2 screws through the hole in the bearing housing. Mount the bellows over the spindle
3.
4.
5.
6.
7.
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PAGE 3.2.17
3.2.5. Adjustment of Left and Right End Stop
1.
Place the spindle/carriage leaving 4.6 +/- 0.5 mm from the bearing housing cover to the spindle nut (see figure 3.2.5.1).
Fig. 3.2.5.1 2. Adjust the left end stop so that the MYCOM sensor is just activated in that position. Use AD conversion to verify the sensor status or use a multimeter. Run a function test of the carriage system. Check PGM parameter 25 which should be approx. 3000 (min. 2500, max. 3500). If necessary, adjust the micron sensor by loosening the bolt and turn the sensor. Run a function test again and check that the PGM parameter 25 is approx. 3000. Move the carriage to the zero point from the PC (Run the carriage 2.5 mm to the right from the MYCOM sensor zero point) Dismount the right emergency stop. From the PC run the carriage 828 mm to the right.
3. 4.
5.
6.
7.
8. 9.
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REV. E
10.
Mount the right end stop and adjust it so that the emergency stop is just activated.
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PURUP IMAGEMAKER MAGNUM FILM LOADER
PAGE 3.3.1
3.3. Film Loader
3.3.1. Magazine
3.3.1.1. Dismounting the Magazine
1.
Dismount all film rolls from the magazine (use the Change Film Roll command on the PC. Tighten the set screw in the left side of magazine no. 1. Open the latches and tilt up the magazine. Remove the threaded coloured knobs and hex. screws on both sides of the magazine. Secure the snip sensor with tape. Remove the outer locking nut on the magazine centre axle. Support the magazine with one hand while removing the gas spring on the left and right-hand side and put the magazine to rest. Remove the belt from the canister drive wheel. Unscrew the centre bolt on the magazine end flanges. Please observe the two thrust washers between the canister and the bracket have the curved side out (convex side outwards)
2. 3.
4. 5.
6.
7. 8.
Note:
9.
Take out the magazine.
3.3.1.2. Remounting the Magazine
1.
Mount the magazine by reversing the procedure described in 3.3.2.1 Dismounting the Magazine. Remember to remove the tape from the snip sensor. Loosen the set screw in magazine no. 1.
Note:
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PAGE 3.3.2
REV. F
2.
Finish the operation.
3.3.1.3. Calibration of Magazine Positioning Switch
1.
Turn the magazine until the micro switch is in the centre of the ring. Insert at slide gauge and adjust the micro switch so that it is not activated at 0.8 mm but actived at 0.9 mm. (see drawing below). Run the automatic magazine test from the Service program. This takes approx. 10 minutes and optimises the SCM parameter 616. If the parameter is between 8-12 it its ok, otherwise you must readjust the micro switch. Please refer to chapter 2.1.
2.
3.
Magazine Slide gauge
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PAGE 3.3.3
3.3.2. Cutting System
3.3.2.1. Replacing the Snip Sensor
1.
Open the cabinet at the top lid, open the latches and tilt up the magazine. Drive the cutter wheel to the centre by hand by pulling the toothed belt. Remove the two fixed screws on the right-hand side for the snip sensor film guide. Loosen the upper left-hand fixed screw, and remove the lower left-hand fixed screw, and tilt up the snip sensor film guide to the left. Remove the defective snip sensor. Remount a new snip sensor and reverse the above procedure. Finish the operation.
3.
4. 5
6.
3.3.2.2. Replacing the Cutting System Belt
Please refer to drawing 5803147 in chapter 10. 1. Open the cabinet at the top lid, open the latches and tilt up the magazine. Drive the cutter wheel to the centre by hand by pulling the toothed belt. Loosen the four screws on the right-hand pulley. Temporarily remount the pulley in the leftmost holes. Loosen the four screws (item 47) on the cutter belt clamp. Remove the belt from the clamp. Remount the new belt by reversing the procedure.
2.
3. 4. 5. 6. 7.
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3.3.2.3. Dismounting and Remounting the Cutting System/ Cutter Wheel
Please refer to drawings 5803146 and 5803147 in chapter 10. 1 Drive the cutter wheel to the centre by hand by pulling the toothed belt (drawing 5803147 item 44) Loosen the four screws on the right-hand pulley (drawing 5803147 (drawing 5803147 item 36) Temporarily remount the pulley in the leftmost holes. Loosen the four screws on the cutter belt clamp. Remove the belt from the clamp (drawing 5803147 item 45) Remove the two fixed screws on the right-hand side for the snip sensor film guide. Loosen the upper left-hand fixed screw, and remove the lower left-hand fixed screw, and tilt up the snip sensor film guide to the left (see drawing 5803146, items 10, 17, 1) Loosen the two bolts for the cutter carriage V-bearings (drawing 5803147, items 10 to 15). Note: These bolts are not metric. Release the lock bolts underneath the carriage. Remove the cutter assembly. Note: The V-bearing have eccentric centre (drawing 5803147, item 14). This allows for firm fit - no play. Exchange the cutter wheel (item 3) by removing the circlip (item 6) from the top and push down the cutter wheel pin (item 4). Take out the cutter wheel without losing the 12 thrust washers (item 5). Insert a new cutter wheel and push through the cutter wheel pin (item 4) and secure it with the circlip (item 6). Note: Be aware of the sharp edges of the cutter wheel and remember that the thrust washers (item 5) are paired two by two, giving a total of five pairs.
2.
3. 4. 5.
6.
7.
9.
10.
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PAGE 3.3.5
11
Remount the cutter carriage. Tighten the V-bearing screws (item 15) with minimal play. Adjust the tension of the cutter wheel carriage by adjusting the V-bearing tension nut (item 14). Secure the V-bearing fixed screws with the double security nuts (item 15). Run the carriage manually to check that tension is the same on both sides of the cutting rail (item 17). Press the cutting wheel spring approx. 1 mm. Adjustments, if any, should be made on fittings no. 36 and 18 on drawing 5803146. Remount the snip sensor film guide. Remount the belt system. Note: The belt clamp should have a full grip over four belt teeth from the left and right side.
12
13.
14.
15. 16.
17. 18.
Remount the right-hand cutter pulley in original position. Finish the operation.
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REV. F
3.3.3. Dismounting and Remounting of Conveyor System
Please refer to the drawing 5803146 in chapter 10. 1. Dismount the magazine: a. Dismount all film rolls from the magazine (use the Change Film Roll command on the PC. Note: Before you start taking things apart, make sure that all voltages are neutralized, e.g. turn service key to on-position.
b. 2.
See chapter 3.3.1.1
Detach all wiring from the loader system, i.e. motors, sensors and switches. In general all wires have to be removed in order to take out the complete conveyor system, i.e. some wires have to be loosened outside the loader and pulled into the loader, e.g. the snip sensor, the tight-loop sensor, and US sensor 1, 6, and 7. Remove the cutter belt, see chapter 3.3.2.2, item 1 to 6. Loosen the conveyor: a. Unscrew the two fixed screws for the conveyor system placed on the top of the drum shoulders on the left and the right-hand side. Loosen the four self-locking screws of the inner guide for the output slit, lift it, and remove it. Loosen the two fixed screws, on each side of the conveyor, for the output slit baffle and push it maximum forward. Note: d. Use 7 mm open-end spanner.
3. 4.
b.
c.
Stand up on the cabinet side, get a good grip of the conveyor and move it up towards the exit slit. Tilt up the front of the conveyor and remove the conveyor.
e.
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PAGE 3.3.7
Note: 5.
This is a two-person operation.
When remounting the Loader System please reverse above procedure. To obtain correct film transport and sufficient vacuum, it is important that the loader frame height is adjusted correctly.
6.
It is not possible to give an exact value for adjustment of the loader as this depends on the individual machine and factors such as the medium (curl, flexibility, etc.). The tool should be seen as a basic adjustment and a check of the loader frame parallellity. The tool consists of the following:
Fixing gadgets -
Adjustment tool
Two fixing gadgets for mounting in the loader frame (solid in the right side, slit in the left for wires). An adjustment tool for measuring distance from the fixing gadgets to the linear system.
3.3.3.1. Procedure
1.
For basic adjustment use the following: Set the height of the adjustment tool to 22 mm by turning the top (measure with digital slide gauge). Mount the fixing gadgets in the two holes on the loader frame, solid in the right side and slit in the left.
2.
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3.
Check that the loader frame is placed correctly and is tightened with the two handles. Push the adjustment tool in between the fixing gadget and the linear system. See the illustration below:
4.
Adjust the loader height on the set screws in the right and left side.
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PAGE 3.3.9
The loader adjustment is a trade-off between unproblematic loading and vacuum fixing, e.g. if the loader is lowered much there will never be load problems but a risk of bad vacuum fixing (with consequent bad exposure quality) and vice versa. Film load can be checked by manually loading a piece of film. Make sure that the film is loaded as closely to the drum as possible without it hitting the drum. Please note that the film will often have more curl at the end of the roll, closest to the film core. 5. Readjust the loader heigh, if necessary. Use the adjustment tool to ensure loader parallellity. Check the ability to fix the medium with vacuum by loading a full size film. Set vacuum on the drum and check that the film is sucked totally in at all corners, especially the rear right corner is critical.
6.
3.3.3.2. Replacing the Conveyor Belts
1. 2. 2.
Remove the magazine as described in chapter 3.3.1.1. Remove the loader system as described in chapter 3.3.3 Place the conveyor system on a table.
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REV. F
3.
Remove the right magazine end flange (do not lose the key for the end flange shaft. Push out the magazine end flange shaft approx. 2 cm. Unscrew the mounting bolts for the conveyor belt axles in the right side of the conveyor (opposite motor side), on either the upper belt section (short belts) or the lower belt section (long belts) depending on position of damaged belts. Note: Use a combination plier to hold the conveyor belt axle if they slip. Be careful not to damage the top points of the conveyor belt axles to avoid damaging the belt tracking zones.
4. 5.
6. 7.
Insert new belts with the printed text inwards. Secure the loader axles with mounting bolts. Note: Use a combination plier to hold the conveyor belt axle if they slip. Be careful not to damage the top points of the conveyor belt axles to avoid damaging the belt tracking zones.
8. 9.
Push through the magazine end flange shaft. Mount the Magazine End Flange on the end flange axle and insert the key. Remount the loader system by reversing the procedure as described in chapter 3.3.3. Remount the magazine as described in chapter 3.3.1.2.
10.
11.
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PURUP IMAGEMAKER MAGNUM LASER
PAGE 4.1.1
4.
Laser
4.1. The Invisible Red (IR) Laser Diode Module (LDM) 488 nm
4.1.1. General Information
TBD
4.1.2. Replacing the (IR) Laser Diode Module
1.
Power down the ImageMaker Magnum and open the cabinet side doors. Remove the bolt fixing the lead screw nut to the carriage and slide the carriage to the right. Loosen and dismount the laser optical fibre from the optical housing. Note: Remember to mount the protection cap on the fibre connector!
2.
3.
4.
Undo all cable ties fixing the laser optical fibre to the carriage and gently pull back the optical fibre. Open the carriage wire carrier, starting from the top, and take out the optical fibre. Loosen and remove the lower front panel, undo all connectors at the IR-LDM, and loosen the four Allen screws for the laser mount plate. Take out the laser mounting plate and demount the IRLDM from the laser mounting plate. Mount the New IR-LDM and reinstall the laser mounting SERVICE MANUAL
5.
6.
7.
8. PURUP PREPRESS A/S
PAGE 4.1.2
PURUP IMAGEMAKER MAGNUM LASER
REV. C
plate in the cabinet. 9. Plug in all connectors and route the laser optical fibre to the optical housing. Close the carriage wire carrier and secure the laser optical fibre to the carriage. Note: Make sure that the fibre is not squeezed by the cable ties, bended, or obstructing the scanning slit area at the middle of the carriage.
10.
11.
Secure the carriage to the lead screw, close the cabinet, and power on the machine. Run a focus film, and set the focus. See chapter 2. Do Film Setup. See the users manual, or chapter 8, appendix 2. a) Run laser power films, all resolutions, measure and evaluate. Key in Laser Power Film patches. Run Density Films, all resolutions, measure and evaluate. Key in Density Film patches.
12. 13.
b) c)
d)
14) Zero set the dot gain calibration on the PS-Link, and expose a new screen adjustment, measure and evaluate. 14. Key in a new dot gain table and expose relevant test films. Finish the operation.
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PURUP IMAGEMAKER VISIBLE RED LASER DIODE
PAGE 4.2.1
4.2. The Visible Red (VR) Laser Diode Module (LDM) 635 nm
TBD
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PURUP IMAGEMAKER MAGNUM FIBRE OPTICS
PAGE 4.3.1
4.3. Fibre Optics
This procedure describes how to replace or adjust the optical fibre on a MAGNUM, configured with an Argon Ion laser. The replacement is described in point A, the adjustments in point B, the ON/OFF measurements in point C, and the laser power setup in point D. Necessary tools: Alignment Kit (Ordered from Purup Prepress) Standard Service Tool Case (Personal SE tools)
TBD
4.3.2. Measuring the ON/OFF Damping Factor in the Optical Fibre
WARNING: This procedure will include dismounting the fibre cable from the optical housing, which may cause the optical alignment to go bad, and it is always necessary to check the alignment by going through chapter 2.4.1 after this service routine! 1. a. Set up the ANRITSU MA 9020A, by using the measuring probe MA 9423A, with extended wire, in pos. OPT-IN, switched to 0.66 microns (660 nm), measuring mW. Switch on and zero-set the meter by pressing SHIFT + OFFSET and wait for approx. 8 seconds for the display to refresh. Note: The sensor inlet on MA 9423A must be covered with the dust cap during zero-setting.
b.
2.
Connect the fibre to the sensor inlet.
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REV. B
3.
Set the laser on by clicking CONTROL + LASER + LASER ON. Set the laser output to the 10 micron power setting value in the film definition file by clicking CONTROL + LASER + SET LASER POWER. Note: You should now have a well-defined output on the ANRITSU MA 9020 A, but you must close the cabinet to avoid daylight getting into the MA 9020A.
4.
5. 6. 7.
Set the laser OFF by clicking LASER + LASER OFF. Switch to dB on the ANRITSU MA 9020A and press REL. Set the laser ON by clicking CONTROL + LASER + LASER ON. Check the readout on the ANRITSU MA 9020A. You should have a readout of more than + or - 37 dB. Note: Argon Ion Laser If the ON /OFF is less than 37 dB, it may be necessary to adjust the fibre again, or the fibre may have a very bad throughput, or the optical loss in the whole optical system is too high and thus has to be isolated by means of simple measurements. IR Laser If the ON/OFF is less than 37 dB, the throughput of the fibre, or the performance of the diode itself is too bad, and the diode must be changed!
8.
Note:
9.
Repeat point 4, 5, 7, 8, 9, and 10, but with 20 micron values. If the results are satisfactory, you can reassemble the MAGNUM. Make a density film, followed by several test films (screening and density). PURUP PREPRESS A/S
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PURUP IMAGEMAKER MAGNUM HRL ARGON ION LASER SYSTEM
PAGE 4.4.1
4.4. HRL Argon Ion Laser System
The High Resolution Laser System (HRL) features a branch of Argon Ion laser and Laser Power Supply, a 250-mhz AOM, and a 250-mhz AOM driver, in order to expose images with 5080 l/mm, equal to 5m pixel size, at a maximum spinner speed of 24000 rpm. In service it is possible to replace any of the HRL Laser System Units and adjust them independently, e.g. the laser tube can be replaced without replacing the AOM, and vice versa. The HRL Laser System consists of the following parts:
HRL Laser System
Argon Ion Laser
Laser Power Supply
250 MHz AOM
250 MHz AOM Driver
Cast Iron Fixture
4.4.2. Replacing HRL Argon Ion Laser
1.
Power down the MAGNUM, open the lower right and left cabinet door, and remove the lower front panel. Demount the power/signal cable from the Laser Power Supply, demount the ventilation duct, release the cable ties fixing the cable and guide the cable outside the cabinet. Note: The cable is very stiff and hard to handle, so please be careful that the cable does not damage any other parts or wirings inside the cabinet.
2.
3.
Loosen the laser tube unit clamps and demount the outer Allen fix screws for the laser tube unit clamps.
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4.
Carefully take out the laser tube unit from the cast iron laser tube unit fixture. Pick up the new laser tube unit and verify that the beam shutter at the front of the laser tube unit is open. If it is not, open the shutter. Demount the fixture for the silicone coupler from the old laser tube unit and mount it on the new laser tube unit. Mount the new laser tube unit into the cast iron fixture, and mount the outer Allen fix screws for the laser tube unit clamps. Note: Make sure that the silicone coupling between the cast iron fixture and the front of the laser tube unit is fitted properly, in order to seal the beam path.
5.
6.
7.
8.
Verify that the new laser tube unit is mounted correctly, see engineering drawing 5801983 in chapter 10.4. before fixing the laser tube unit clamps. Route the power/signal cable to the laser power supply and fix the connector with the two finger screws. Organise the power/signal cable inside the cabinet frame and fix it to the right side of the terminal box of the laser tube unit with one cable tie, and the cast iron laser fixture with three cable ties, see engineering drawing 5801983 in chapter 10.4. Power up the MAGNUM and adjust the tube current/operating voltage and alarm limit, see item 4.4.3., points 6, 7 and 8, in this chapter. Adjust the AOM, see item 4.4.9 in this chapter. Adjust the optical fibre, see item 4.4.7. in this chapter. Find the ideal focus point for the MAGNUM, see chapter 2, item 2.1.2.8. Find the ideal density for the MAGNUM, see chapter 8. PURUP PREPRESS A/S
9.
10.
11.
12. 13. 14.
15. SERVICE MANUAL
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PURUP IMAGEMAKER MAGNUM HELIUM-NEON LASER SYSTEM
PAGE 4.5.1
4.5. Helium-Neon Laser System 4.5.1. General Information The Helium Neon Gas Laser System (He-Ne) features a branch of He-Ne visible red, 635 nm laser and Laser Power Supply, a crystal AOM, and AOM driver, in order to expose images with 3175 dpi at a maximum spinner speed of 24000 rpm. The He-Ne laser is an open-loop system without beam splitter and feedback as known from the HRL and the Siemens laser systems. This makes replacement/adjustment of individual parts easier than known from the HRL laser system. There is thus no adjustment for the laser PSU upon replacement of the laser or the PSU. In service it is possible to replace any of the He-Ne Laser System Units and adjust them independently, e.g. the laser tube can be replaced without replacing the AOM, and vice versa. The driver is the same as used with a HRL laser, however, laser, laser PSU and modulator are different from those of the HRL. The He-Ne Laser System consists of the following parts:
He-Ne Laser System
He-Ne Laser
Laser Power Supply
250 MHz AOM
250 MHz AOM Driver
Cast Iron Fixture
4.5.2. Replacing He-Ne Laser
1.
Power down the MAGNUM, open the lower right and left cabinet door, and remove the lower front panel. Demount the power cable from the Laser Power Supply. Loosen the laser tube unit clamps and demount the outer Allen fix screws for the laser tube unit clamps. Carefully take out the laser tube unit from the cast iron
2. 3.
4.
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laser tube unit fixture. 5. 6. Pick up the new laser tube unit. Demount the fixture for the silicone coupler from the old laser tube unit and mount it on the new laser tube unit. Mount the new laser tube unit into the cast iron fixture, and mount the outer Allen fix screws for the laser tube unit clamps. Note: Make sure that the silicone coupling between the cast iron fixture and the front of the laser tube unit is fitted properly, in order to seal the beam path.
7.
8.
Verify that the new laser tube unit is mounted correctly, before fixing the laser tube unit clamps. Route the power cable to the laser power supply and fix the connector. Power up the MAGNUM and let the laser warm up for approx. 30 minutes. Adjust the AOM, see item 4.4.8 in this chapter. Adjust the optical fibre, see item 4.4.5. in this chapter. Find the ideal focus point for the MAGNUM, see chapter 2, item 2.1.2.8. Find the ideal density for the MAGNUM, see chapter 8. Due to the high output from the He-Ne laser, it may be necessary to reduce the output power by tuning the trim potentiometer on the AOM driver to a lower AOM driver work point. See item 4.5.4 for further information.
9.
10.
11. 12. 13.
14. 15.
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PAGE 4.5.3
Fig. 4.4.5.1
16.
Verify the MAGNUM exposure performance, see chapter 2, item 2.5.
4.5.3. Replacing He-Ne Laser Power Supply
1.
Power down the MAGNUM, open the lower right cabinet door. Demount the power cable from the Laser Power Supply and demount the mains power cable from the laser module frame. Demount the laser power supply and pull it out from the cabinet. Remount the new laser power supply by reversing point 3 and 2. Power up the MAGNUM, wait for the laser to start, and let the laser warm up for 30 minutes.
2.
3.
4.
5.
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6.
Find the ideal density for the MAGNUM, see item 4.5.2, item 15. Note: The laser power supply is supplied in two versions for 115 V and 230 V, respectively. The difference is the cable connections illustrated in the table below:
115 V Blue Yellow/green Brown White N/C Earth 115 V Neutral 230 V Blue Yellow/green Brown White Neutral Earth 230 V N/C
From PP Production the 110 V is marked (no mark on 220 V). Please mark the power supply if you change the cabling.
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PAGE 4.4.3
16.
Verify the MAGNUM exposure performance, see chapter 2, item 2.5.
4.4.3. Replacing HRL Laser Power Supply
1.
Power down the MAGNUM, open the lower right cabinet door. Demount the power/signal and interface cable from the Laser Power Supply and demount the mains power cable from the laser module frame. Demount the finger fix screws for the laser power supply plate, and pull it out from thecabinet. Remount the new laser power supply by reversing point 3 and 2. Note: Remember to set the laser power supply to Current Mode Power up the MAGNUM, wait for the laser to start, and let the laser warm up for 10 minutes. Connect a voltmeter to the laser power supply monitor board, TP2 = GND, and TP3 = current MON, and set SW1 to CURRENT MODE, if not already done. See drawing 5601553 ST in chapter 10.3. Set the alarm limits for this new laser tube by adjusting the tube current to 700 mV, equal to 7.0 Amps tube current, and AD convert PGM channel 27, see also item 10.2 and item 2.1.2.2.2, Bitbus AD conversion. Change PGM parameter 3, and enter the AD conversion result as PGM parameter 3. See also item 2.1.2.1.1, Parameters. Mount the Anritsu laser power meter on the fibre as described in 4.4.6 item 3 and 4. Turn the security to off position and set the laser on with maximum power 4090. Switch to Light Mode and adjust R1 until you have 2.5 mW on the Anritsu (nominal 1.14 multiplied by a factor 2.19).
2.
3.
4.
5.
6.
7.
8.
9.
10.
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PAGE 4.4.4
REV. C
11.
Check that the reading on the multimeter does not exceed 550 mV, equal to 5.5 Amps tube current. If the tube current exceeds 5.5 Amps at an output of 2.5 mW with optimum adjusted modulator, modulator driver, and fibre, the tube cannot be used in the Magnum. Demount the multimeter and close the MAGNUM cabinet. Find the ideal density for the MAGNUM, see chapter 8, item 2.3.1.2. Make a backup of machine parameters, see item 2.3.4.
12.
13.
14.
4.4.4. Replacing HRL AOM Driver
1.
Open the upper right door, with the MAGNUM running and indicating "waiting for job", and set "off line". Note: Ignore the voltage error alarms on the PC.
2. 3.
Open the lower right door of the MAGNUM. Unplug the connectors from the modulator driver and demount the driver from the cabinet frame. Mount the new modulator driver and plug in the connectors. Close the upper right doors of the MAGNUM. Select STATUS + FILM PLACEMENT + FIND AND EJECT FILM on the PC. Adjust the AOM driver power by placing the power meter probe Anritsu MA 9020A with MA9022a (extended wire) in pos. OPT - IN, switched to 780 nm, measuring the output power from the first order beam at the drum surface. Tune the trim potentiometer on the AOM driver to maximum or fully cw. While observing the laser output on the powermeter, tune the potentiometer ccw and note PURUP PREPRESS A/S
4.
5. 6.
7.
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PAGE 4.4.5
the output power increases and decreases again. Fine-tune the AOM driver until you have the highest output on the first order beam. See figure 4.4.4.1.
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PAGE 4.4.6
REV. C
Fig. 4.4.4.1
Demount the powermeter, seal the adjustment hole on the AOM driver and close the lower right cabinet door.
8.
Make a density film for all the different units mounted in the MAGNUM and expose several test films.
4.4.5. Replacing the HRL Optical Fibre
1.
a.
Demount the old fibre from the MAGNUM, by loosening it on the optical housing. Release all cable ties and cable carrier. Pull back the fibre into the lower cabinet compartment.
b. c.
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PAGE 4.4.7
Note:
Cover the fibre attachment fitting on the optical housing to avoid any dust particles from entering into the fibre fitting and into the optics.
2.
Remove the protection cover for the fibre fixture and loosen the fibre fix spring screw. See technical drawing no. 5801983, pos. 56-61 for further information in chapter 10.4. Pull out the fibre from the fibre fixture assembly. See technical drawing no. 5801983, pos. 56-57 for further information (chapter 10.4). Mount the new fibre into the fibre fixture and tighten the fibre for spring screws, not so tight, however, that you cannot to turn the fibre basis in the fibre fixture assembly. a. b. c. Remove all tools. Mount the rubber protection cap on the fibre. Route the optical fibre into the cabinet, cable carrier and carriage to the optical housing, and connect it. Make sure that the fibre connector guide pin is fitted correctly into the optical housing and carefully tightened. Mount the protection cap.
3.
4.
5.
Note:
6.
a.
Route the surplus fibre in a loop on the carriage and make sure that the fibre is not bent, squeezed, or in any way stressed by surrounding modules. Do not fix the fibre with cable ties!
Note: b.
Fix the fibre loop with loose cable ties and tighten them carefully.
4.4.6. Adjusting the Optical Fibre
1)
Open the left door, with the MAGNUM running and indicating waiting for job, and set it off-line. Note: Ignore the voltage-error alarms on the SERVICE MANUAL
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MAGNUM PC. 2) Open the lower right door, entering the laser compartment of the MAGNUM. Remove the protection cap and unplug the optical fibre from the optical housing and plug it into the laser power meter (LPM), ANRITSU MA 9020A, equipped with sensor MA9423A. Note: It is convenient to have the cabinet front plate dismounted and the electronic module plate lowered in order to get a better view of the LPM.
3)
4)
Switch on and zero-set the LPM by pressing SHIFT+OFFSET. Wait for approx. 8 seconds, and the display will refresh. Note: If the LPM will not zero-set, it is necessary to unplug the optical fibre from the LPM and make a new zero-setting.
5)
Turn the security key to OFF position, set the laser on with a suitable laser power by means of the service program. See also item 2.1.2.13. Note: * * If the LPM indicates laser output from the fibre, go to point 17. If the LPM does not indicate laser output from the fibre, go to point 6.
6)
Remove the protection cover for the fibre fixture, loosen the fibre fix screw, and pull the fibre out of the fibre fixture. See technical drawing 5801983 pos. 56-58-8-61, chapter 10.4, for further information. Note: Both the fix screw (56) and the spring screws (58) must be loosened considerably in order to remove the fibre from the fibre fixture, and the operation described in point 6 should be fulfilled.
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PAGE 4.4.9
7)
Place a piece of paper (address label or other pre-glued paper) and let it obstruct the beam in order to keep track of the laser beams. Note: You should now be able to see the modulated laser beams on the paper, as seen in figure 4.4.7.1.
Preferred 1'order, position marked with a pen Figure 4.4.7.1.
8)
Isolate the preferred 1st order to the left of the Main Beam (MB), and mark it. Note: Unplug/Plug in the DC power for the AOM Driver to determine the exact position of the preferred 1st order beam, and mark it with a cross.
10) Mount the fibre preadjustment tool into the fibre fixture with the lens pointing out in order to adjust the fibre in angular direction. See figure 4.4.7.2.
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Note:
The preadjustment tool has to be fully in and the spring screws hand-tight. Only adjust on the Angular adjustment screws, if the preadjustment tool is mounted for Angular adjustment, and only adjust on the Parallel adjustment screws, if the preadjustment tool is mounted for Parallel adjustment, see also figure 4.4.7.2.
Note:
10) Adjust the front adjustment screws of the fibre fixture in order to position the silhouette of the 1st order beam in the middle of the cross mark, see figure 4.4.7.3.
Figure 4.4.7.3 11) Loosen the spring screws on the fibre fixture, pull out the preadjustment tool, turn it 180 degrees so that the lens inside the preadjustment tool has the parallel position, put it into the fibre fixture, and tighten the spring screws. 12) Adjust the rear adjustment screws of the fibre fixture in order to position the silhouette of the 1st order beam in the middle of the cross mark, see figure 4.4.7.3. 13) Loosen the spring screws on the fibre fixture, pull out the preadjustment tool, turn it 180 degrees so that the lens inside the preadjustment tool has the angular position, put it into the fibre fixture, and tighten the spring screws. Note: SERVICE MANUAL Continue point 11, 12, 13, and 14 until the PURUP PREPRESS A/S
REV. C
PAGE 4.4.11
beam stays in the cross mark. 14) Loosen the spring screws, and pull out the preadjustment tool. 15) Mount the fibre basis into the fibre fixture and handtighten the spring screws. 16) Adjust the front (angular) adjustment screw on the fibre fixture until you have maximum output on the LPM. 17) Adjust the rear (parallel) adjustment screw on the fibre fixture until you have maximum output on the LPM. 18) Fine-tune the output with all adjustment screws in action, in order to obtain maximum output from the fibre. 19) Tighten the fix screw for the fibre basis while observing that the output does not drop on the LPM, and mount the protection cover for the fibre fixture. 20) Verify that the beam adjusted through the fibre is the 1st order beam by unplugging/plugging in the DC power for the AOM driver. 21) Make an ON/OFF measurement on the laser unit, see item 4.3.2. 22) Demount the LPM, and mount the fibre unto the optical housing. Note: Remember to check that the fibre coupler is inserted correctly into the optical housing.
23) Remove the tools, close the MAGNUM cabinet, turn the service key to ON position, and make a restart of the USER/SERVICE program. 24) Make a new density film, see chapter 8. 25) Verify exposure performance and run test films 1201 and 1202. See item 2.5. 26) Finish the operation. PURUP PREPRESS A/S SERVICE MANUAL
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4.4.7. Replacing the HRL AOM
1)
Open the upper right door with the MAGNUM running and indicating waiting for job, and set it "off-line". Note: Ignore the voltage-error alarms on the MAGNUM PC.
2)
Open the lower right door, entering the laser compartment of the MAGNUM. Remove the protection cover for the fibre fixture, loosen the fibre fix screw, and pull the fibre out of the fibre fixture. See technical drawing 5801983 pos. 56-58-8-61, chapter 10.4, for further information. Note: Both the fix screw (56) and the spring screws (58) must be loosened considerably in order to remove the fibre from the fibre fixture.
3)
4)
Unplug the DC power for the AOM driver, unplug the AOM BNC cable from the AOM driver and loosen all relevant cable ties in order to free the cable. Loosen the four fix screws for the AOM fix plate, destress the AOM cable and lift away the complete AOM assembly. See also drawings Z00-T005, positions 2 and 3, and drawing 5801983 in chapter 10.4 for further information. Loosen the SMA connector and the four fix screws for the AOM, and remove the AOM. See position 34 on drawing 5801983. Install a new AOM in the original place with the SMA connector pointing in the correct direction (inwards), and fix the AOM with the four fix screws. Note: If no other screws have been loosened, go to point 9.
5)
6)
7)
8) SERVICE MANUAL
Verify the physical default settings of the AOM, see PURUP PREPRESS A/S
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PAGE 4.4.13
figure 4.4.8.1.
Default AOM hight => 5mm AOM Fix Rod
AOM Fixture AOM Fix Plate
AOM
Figure 4.4.8.1.
9)
Connect the SMA cable to the AOM, mount the AOM assembly into the cast laser-bed and fix the dust rubber sealer at the rear of the laser-bed. Note: Be careful not to bend or squeeze the BNC cable, as this can affect the stability of the AOM during operation.
10) Verify that the main laser beam passes through the AOM in the optimum way. Slide the AOM fix plate in/out until the best result is obtained, and fix the four fix screws in that position. See also figure 4.4.8.2.
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Optimum Beam Path In the AOM AOM Fix Rod AOM Fixture AOM Fix Plate
AOM
Laser Main Beam Laser Bed Figure 4.4.8.2.
Fig. 4.4.8.2 11) Go to item 4.4.9, adjusting the HRL AOM.
4.4.8. Adjusting the HRL AOM
1)
Open the upper right door, with the MAGNUM running and indicating waiting for job, and set it off-line. Note: Ignore the voltage-error alarms on the MAGNUM PC.
2)
Open the lower right door, entering the laser compartment of the MAGNUM. Set up the laser power meter (LPM), ANRITSU MA 9020A, equipped with sensor MA9422A (extended wire). Switch on and zero-set the LPM by pressing SHIFT+OFFSET. Wait for approx. 8 seconds, and the display will refresh. If the LPM will not zero-set, it is necessary to mount the dust cab on the LPM and make a new zero setting.
3)
4)
Note:
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PAGE 4.4.15
5)
Turn the security key to OFF position, set the laser on with a suitable laser power by means of the service program. See also item 2.1.2.13. Remove the protection cover for the fibre fixture, loosen the fibre fix screw and pull the fibre out of the fibre fixture. See technical drawing 5801983 pos. 56-58-8-61, chapter 10.4, for further information. Note: Both the fix screw (56) and the spring screws (58) must be loosened considerably in order to remove the fibre from the fibre fixture.
6)
7)
Mount a piece of paper outside the MAGNUM cabinet, in order to keep track of the laser beams. Note: You should now be able to see the modulated laser beams or some of the modulated beams on the paper, as seen in figure 4.4.9.1.
Preferred 1'order, position marked with a pen Figure 4.4.9.1.
8)
Mount the AOM adjustment tools, as shown in drawing Z00-T005, in chapter 10.4. Mount the LPM probe on the holder plate and let the preferred 1st order beam enter the 2-mm hole, drilled in the dust cover for the LPM probe. Note: If the hole is not drilled, it is a very easy operation for you to do yourself.
9)
10) Adjust the AOM driver to maximum drive power. 11) Loosen the fix screws, position four screws seen in drawing Z00-T005, and optimize the output of the 1st
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order beam by adjusting UP/DOWN or ANGULAR. Note: When adjusting UP/DOWN, the micrometer screw, pos.12 in Z00-T005, must be slightly lose in order for the adjustment arm to move upwards/downwards. When adjusting ANGULAR, the fix screw, pos.15 in Z00-T005 must be slightly loose, in order for the adjustment arm to turn.
Note:
12) Optimize the AOM adjustment until the 1st order beam is maximum and fix the AOM in that position. Note: Be aware that the laser output does not decrease when fixing the AOM.
13) Adjust the AOM driver, see item 4.4.4, point 7. 14) Measure both the main beam and the 1st order laser output when the AOM is switched ON/OFF, respectively, and enter these measurements in the formula shown in figure 4.4.9.2, below.
1'order output (mW) ______________________ Main Beam output (mW) = Efficiency rating (%)
Fig. 4.4.9.2 Note: The efficiency rating must be better than 80% for optimum modulation.
15) Demount the tools and go to item 4.4.7. and adjust the laser fibre.
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PAGE 4.3.3
4.3.3. Defining New Power Settings for the Film Definition File
1.
Find the new film definition laser power setting for 10 microns, by measuring the output from the spinner head. a. Set up the ANRITSU MA 9020A, by using the measuring probe MA 9422A with extended wire, in pos. OPT-IN, switched to 0.66 m (660 nm), measuring mW. Switch on and zero-set the meter by pressing SHIFT + OFFSET and wait for approx. 8 seconds for the display to refresh. Note: The sensor inlet on MA 9422A must be covered with the dust cap during zero-setting.
2.
b.
3.
Set the laser on by clicking CONTROL + LASER + LASER ON. Set the iris to the 10 micron value by clicking CONTROL + IRIS + POSITION IRIS. Set the laser output to the 10 micron power setting value in the film definition file by clicking CONTROL + LASER + SET LASER POWER. a Open the left door of the MAGNUM and position the measuring head in the drum. Direct the laser beam into the probe by moving the probe and turning the spinner head manually. Use the IR track paper if you have an IR laser. Note: You should now have a well-defined output on the ANRITSU MA 9020 A.
4.
5.
6.
b.
c. 7.
Close the cabinet to avoid measuring daylight!
Set the laser off, by clicking LASER + LASER OFF, and press REL on the ANRITSU MA 9020A.
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8.
Set the laser on by clicking CONTROL + LASER + LASER ON. Verify that the output is approx. 15 W. If not, change the laser power by clicking CONTROL + LASER + SET LASER POWER. Note: When you have found the power setting, where the laser output is 15 W, you can write these figures down, and key them into the film definition file as the power value for 10 microns.
9.
10.
Set the iris to the 20 micron value by clicking CONTROL + IRIS + POSITION IRIS. Set the laser output to the 20 micron power setting value in the film definition file by clicking CONTROL + LASER + SET LASER POWER. Set the laser off, by clicking LASER + LASER OFF, and press REL on the ANRITSU MA 9020A. Set laser on by clicking CONTROL + LASER + LASER ON. Verify that the output is approx. 30 W. If not, change the laser power by clicking CONTROL + LASER + SET LASER POWER. Note: When you have found the power setting, where the laser output is 30 W, you can write these figures down, and key them into the film definition file later.
11.
12.
13.
14.
15.
a.
Exit to the Main menu, enter Configuration menu, enter CHANGE FILM DEFINITIONS. Select the film definition file that you want to change, and key in the new power values for 10 microns and 20 microns.
b.
16.
Enter the GAMMA curve menu and change the start and stop values for the density film, so that the start and stop PURUP PREPRESS A/S
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value are below and above the film definition power values, in wanted steps. 17. Exit to the Main menu, start the User menu, and make a density film as described in the MAGNUM User's Manual.
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PURUP IMAGEMAKER MAGNUM BITBUS MODULES
PAGE 5.1.1
5.
Electronics
The Purup ImageMaker MAGNUM is controlled by a PC, equipped with a Bitbus Master Board, running the INTEL Bitbus Program. The Bitbus Master Board communicates with 6 modules inside the MAGNUM, all connected on the same bitbus network. A diagram is shown below:
5.1. Bitbus Modules
Figure 5.1.1. Diagram of the Bitbus Modules
Start Up/Initialization When the MAGNUM is powered on, the PC will start to download program data to the modules inside the MAGNUM when the Bitbus system is initialized. The modules are interactive, i.e. they work independently of the downloaded program.
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The hardware of the SCM modules is totally identical, i.e. the function of the SCM modules is given by the physical position of the SCM and the control software downloaded to the individual SCM.
Figure 5.1.2. Physical Position of Modules and Function
5.1.1. Bitbus Master
The Bitbus Master board is a standard plug-in PC board. The Bitbus Master board controls the PGU (PGM & BTM), and the SCMs with the ImageMaker software version 6.xx on the PC. The ImageMaker software operates with more than 120 command files which are downloaded on the Bitbus Network to each of the individual modules.
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5.1.2. Pixel Generator Unit
The PGU contains the Bitbus Taxi Module (BTM) and the Pixel Generator Module (PGM). The PGU controls the whole synchronisation of the exposure process in the MAGNUM. The BTM receives bitmap data from the PS-Link and places the data into the FIFO buffers of the PGM, whereafter they are exposed directly.
Pixel Generator Unit 3, 4 or 5 resolutions, 1270/2540/3175/3969/5080 dpi, 20/10/8.4/6.4/5 The MAGNUM equipped with the High Resolution Laser Argon Ion can output in resolutions of 1270, 2540, 3175, 3969, and 5080 dpi. The MAGNUM equipped with the LDM IR-Laser can output in resolutions of 1270, 2540, 3175dpi. The LDM VR-Laser can expose 1270, 2540, 3175, and 3969 dpi.
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5.1.2.1. Replacing the Pixel Generator Unit
1.
Turn off the MAGNUM, open the upper left and the right door and remove the upper front plate of the cabinet. Loosen the two fix screws for the electronics module plate and fold it down. Loosen the two fix screws for the PGU, and with a firm grip on the PGU enclosure, pull the PGU module off from the PGU connecter board and lift it away from the electronics module plate. Mount the new PGU, by reversing the entire operation. Await the start of the MAGNUM and notice messages on the PC monitor. Expose relevant test films. Finish the operation.
2.
3.
4. 5.
6. 7.
5.1.2.1.1. Bitbus TAXI Module
The BTM carries out the communication between the VTM (VSB Taxi Module) in the PS-Link and the Purup ImageMaker. The BTM receives bitmap and control data from the PS-Link via FDDI. Bitmap data are distributed to the PGM (Pixel Generator Module), and control data are distributed to the Bitbus system.
5.1.2.1.2. Replacing the Bitbus TAXI Module
The Bitbus TAXI module is an integrated part of the PGU and is replaced with the PGU, see item 5.1.2.1.
5.1.2.2. Pixel Generator Module
The PGM receives parallel data from the BTM, converts them into serial data, and synchronizes them with the spinner. The serial data flow through the laser and via an optical fibre to the optical system. A Bitbus CPU controls and monitors the process.
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The spinner encoder emits the synchronizing clock which is multiplied by 160 in a phase lock loop (PLL). The result is 160,000 pulses per spinner revolution equivalent to a resolution of 5 on the film. The spinner rotates at 24,000 rpm with a synchronizing clock frequency of 64 MHz. Bitmap data from the Bitbus-TAXI module are read into the FIFO. Size: 1 scan line = 32 K x 8, and the speed: 7 Mbyte/s
While one scan line is clocked to the laser, another scan line must be read in order to avoid an exposure interruption. Bitmap data from the FIFO are transformed into serial form by means of the pixel clock. Serial signals are controlled by the Bitbus CPU. Serial data are synchronized completely with PixelCLK by a flip-flop. Positive or negative film. Signals are transmitted via an XOR gate. Controlled by a Bitbus CPU. On/off control of the laser by means of Bitbus CPU. Default data control.
Controls reading of bitmap data into FIFO. For every byte written in FIFO, WRITE COUNT adds 1. WRITE COUNTER is transferred to READ COUNTER when a new scan line is read out. Signals for Bitbus-TAXI module: Signal WRREQ WRITE WRDY Function Write request Write clock FIFO ready Type TTL TTL TTL Number of pins 1 1 1
The Read Control is the superior synchronization of the pixel generator, and all synchronizing signals are generated from 5 signals.
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Input
1. 2. 3. 4. 5. 1. 2.
Pixel clock (PCLK) Logic zero pulse Terminal count Ready RUN/STOP FIFO-RD Shift register - load
Output
Input Signal Description 1. PCLK. Generated by PLL from the spinner encoder. Frequency : 64 MHz. Zero pulse. Generated by offset counter. 1 pulse per spinner revolution = 1 pulse per scan line. Frequency : 200 Hz. Terminal count. Generated by read counter. Signals when there are no more bytes in the scan line. Ready. Request from write control to start a new scan line. RUN/STOP. FIFO-RD and shift register load are not generated when RUN/STOP signals stop.
2.
3.
4.
5.
Output Signal Description 1. 2. FIFO-RD. Request to FIFO to read a byte. Shift register load. Request to shift register to read a byte from FIFO to shift register.
Offset Counter (Start of Scan) The start point of a scan line in horizontal direction is set by the spinner encoder zero pulse. As it can be placed in any position, it is necessary to be able to add an offset to this position. The zero pulse is read during start up. PCLK then generates a logic zero pulse, setting the start of the scan line.
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The resolution of offset and the logic zero pulse is 10 m equivalent to 80,000 pulses per scan line, i.e. a 16 bit counter can set the logic zero pulse. Accuracy should be as PCLK. Offset counter is controlled by Bitbus CPU 1 on the PGM. PLL The pixel clock (PCLK) is generated from the spinner encoder clock. Depending on the spinner speed, the clock is multiplied by 320 or 160 in a phase lock (PLL). . The output from the VCO (voltage controlled oscillator) is always 64 MHz. By multiplexing the output from a divider, the wanted output clock can be obtained. There are two outputs from the PLL, pixel clock (PCLK) and offset clock. The offset clock is input to the offset counter. Spinner Control The motor is a 3-phase, 4-pole DC brushless motor. In order to control the spinner driver, the following signals must be available: Signal to ON/OFF Signal to 12000/24000 rpm Spinner encoder feedback 3 signals for motor commutation Signal for overload
The physical zero pulse of the encoder is used for setting the time of commutation for the motor. The encoder has 1000 pulses per revolution. The motor is 4-poled, the encoder pulses are stepped down to 2 pulses per revolution. Commutation frequencies: 12000 rpm 24000 rpm 400 Hz 800 Hz
The Linear System The spindle motor can control the spindle in 2 modes: PURUP PREPRESS A/S SERVICE MANUAL
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1.
Synchronous motion with the spinner as master. During exposure the spindle clock uses SPCLK to control the stepper motor as the carriage is a slave of the spinner. SPCLK is stepped down by the pixel clock PCLK. Step down : 5 : 10 : 20 : 6400 1600 400
2.
CPU generated pulses. Are used when the carriage is placed in position.
CPU 2 is a slave of CPU 1. Communication between the 2 CPUs are made via a dual port RAM and an interrupt channel. Stepper motor frequency : End Stops Type : IR Switch max. 100 kHz
Controlled from bitbus CPU 1. Stepper motor CPU receives end-stop status by means of the internal signals. Emergency End Stops Part of the safety circuit, the safety loop. The CPU monitors status on the signals. Run/Stop (run/wait lines) If the pixel generator does not receive bitmap data sufficiently fast, the carriage runs X scan lines backwards and X scan lines forwards to continue exposure. 10 < X < 127. The circuit should simulate scan lines without transmitting data to the laser. The read control stops the following signals: 1. 2. 3. CPU FIFO - RD Shift register - load Pixel data
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Bitbus processor 8044 monitors the process on the module. The process is controlled by means of programs downloaded from the PC. The CPU is connected in mode with external code and data memory, which is also physically placed in the same memory. CPU 1: CPU 2: 8044 Bitbus Enhanced Micro Controller 8031 Micro Controller
There are 2 CPUs on the PGM. Linear motion (CPU 2) is slave of the Bitbus CPU (CPU 1). Bitbus CPU 1 has the superior control of the module. The CPU controls the following functions: 1. 2. 3. 4. 5. 6. 7. 8. Pixel control Offset PLL Laser diode control Spinner control Master for "linear motion" CPU Linear motion control Built-in self-test
Watchdog and Safety System For protection against CPU errors, each of the pixel generator CPUs has a watchdog function. This watchdog monitors the 5 V supply voltage and the CPU. The watchdog is disabled when starting. CPU 1 Besides resetting the CPU when an error occurs, the watchdog is connected to the safety system so that the supply voltage to motors and other actuators in the entire machine is interrupted when errors occur. An interruption of the safety loop is read by the CPU, and status is given in the LCD display. CPU 2
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This watchdog only affects the CPU 2. ID Code An 8 bit ID code can be read from an EPLD by the CPU. The ID code indicates the board's revision status, and the status is displayed on the PC user program, VERSION. A/D Converter All signals are conducted to a number of multiplexes, which select the input to be converted. The A/D converter contains two registers, one where the 8 MSB can be read, and one where the 4 LSB and a status bit can be read by the CPU. The status bit indicates when the A/D conversion is completed. It is sufficient to read one register, register 1, if the conversion does not require a high accuracy. Use the AD conversion list in chapter 10, and follow descriptions given in chapter 2.
5.1.2.2.1. Replacing the Pixel Generator Module
The Pixel Generator module is an integrated part of the PGU and is replaced together with the PGU, see item 5.1.2.1
5.1.3. Scanner Control Module
The scanner control module is a general module of which 3 as default and up to 4 are used in the MAGNUM. The module contains all functions necessary for controlling the machine except for control of bit map data, linear motion, and spinner motor. This function is carried out by the PGU. The SCM module is controlled by a Bitbus CPU which is slave of the Bitbus master, mounted in the PC.
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The Scanner Control Module consists of an Intel 8044/8344 CPU which has to control a multiple of interfaces to stepper motors, DC motors, transducers, DC drivers, ultrasound drivers, etc. Also, the SCM consists of RAM memory, Prom memory, interrupt controller, watchdog circuit, security circuit, and an A/D-converter for monitoring the process. The program code to control the logic is down-loaded to the SCM memory during initialization of the laser imagesetter system and communication to the SCM takes place by means of the Bit-Bus link which is controlled from the BBM. The Bit-Bus link meets the Bit-Bus interconnect concept given by Intel cooperation and is based on a serial bus optimize for high speed transfer of short control messages. Design The SCM is primarily designed in C-MOS SMD (Surface Mounted Device) technology to ensure high density of electronics on minimum space. The SCM consists of two printed circuit boards, a controller board and a driver board, which are interconnected by means of three flat cables; both boards are designed in four layer multi layer board technology. The controller board mainly consists of the digital and analog electronics as well as interfaces to drivers and input/output stage. The driver board consists of all power electronics, EMC (Electro Magnetic Compatibilities) filtration and connectors for ext. interface. The final product of the SCM is assembled in a "sandwich" construction covered by a heat sink which is a part of the enclosure. Monitoring For monitoring the process on the module, Bitbus processor 8044/8344 is used, which is an extended version of the 8051 processor including an intelligent serial communication controller that supports the HDLC/SDLC protocol. Therefore, the control logic to control the CPU and arbitration is nearly the same as used for design with the 8051 processor, except for the serial interface. The process is controlled by means of programs downloaded from the PC.
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Memory The SCM is exclusively equipped with RAM. The RAM contains both the downloaded program code and data. The RAM is a static type, 2 X 32 K * 8. The CPU has access to the 64 Kbyte memory. The control logic selects program code or data memory space, and the program code is executed from external PROM which is customer programmed. Clock Generator The clock generator is built on a 12 MHz crystal and two dividers (U33, U53), which generate different clock signals.
System Clock Spindle motor clock Watch Dog clock Master Clock for timer Ultra Sound driver, A/D Converter SYCLK = 12 MHz STMCL = 375 KHz WDCLK = 732 Hz TIMCLK2 = 6,0 MHz ADCLK = 1,5 MHz U53 pin9 U53 pin5 U53 pin3 U33 pin9 U33 pin6 (TP312)
Reset Logic The reset circuit consists of a voltage supervisor (U2) which internally includes a voltage comparator with its threshold given as 4,55V typ. If supply voltage measured in the farthest corner of the SCM controller board drops below 4,55V, the supervisor is generating a reset signal for the SCM. An external reset activated from the watch dog circuit greater than 400nsec will perform a system reset on SCM. Watchdog Logic The watch dog logic is integrated in a PLD circuit, and a reset signal to U2 is generated when the following conditions occur: If reset push button is activated (SW4) - hardware reset. If no clear pulse is generated from the software - WDCLR pulse. If Software security bit is not present at U27-DB5 (SWSEC).
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During power up of the system, the watch dog (U34) is disabled until firmware and configuration is loaded and running. After initialization the SWSEC signal is set to inform the watch dog about successful initialization, then the software enables the watch dog, and the security circuit is enabled. Hereafter the watch dog has to be cleared. Otherwise, a watch dog timeout occurs. If a timeout occurs, the watch dog disables the security circuit, and "C" occurs on the display to tell the user that a watch dog reset was present. The status bit is present when the system is reinitialize and a diagnostic is executed.
5.1.3.1. Replacing Scanner Control Module
1. 2. 3.
Turn off the MAGNUM and open the cabinet top. Locate the selected SCM. Loosen the fix screws for the SCM, and with a firm grip on the SCM enclosure, pull the PGU module upwards from the SCM connecter board, and lift it away. Mount the new SCM, by reversing the entire operation. Await the start of the MAGNUM, and notice messages on the PC monitor. Expose relevant test films. Finish the operation.
4. 5.
6. 7.
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PURUP IMAGEMAKER MAGNUM DRIVER MODULES
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5.2. Driver Modules
This chapter contains information about the spinner and the spindle driver, mounted in the lower cabinet section of the MAGNUM.
The stepper motor driver and the spinner driver are directly controlled by the PGM, however, the reference signal for the total synchronisation is the spinner encoder. For further information, see item 5.1.2.3 Pixel Generator Module.
5.2.1. Spinner Driver
The spinner driver has the purpose of driving and controlling the spinner at the configured speed. The MAGNUM is equipped with a WestWind Air bearing spinner unit, default configured for 24000 rpm, driven by a WestWind PLL spinner driver.
5.2.1.1. Replacing the Spinner Driver
1.
Open the upper right door of the MAGNUM, observe that the spinner stops, and open the lower right door, in order to get access to the spinner driver
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2.
Unplug the DC power for the spinner driver first, and unplug the rest of the connectors next. Loosen the spinner driver from the fixtures, remove it and install the new spinner driver. Plug in the connectors, first the signal cables, and finally the DC power connection. Close the upper right cabinet door. Select STATUS/FILM PLACEMENT/FIND & EJECT FILM, to make a clean up. Load the service program, and measure the spinner speed, see also item 2.1.2.14. Air spinners must run either 12000 or 24000 r.pm. automatically, depending on the configured speed, as they are PLL drivers.
3.
4.
5. 6.
7.
Note:
5.2.2. Stepper Motor Driver
The stepper motor driver provides current supply pulses for the 5 windings corresponding to each of the 5 phases of the stepper motor and controls the direction of movement (CW/CCW) of the stepper motor. The stepper motor driver is mounted next to the DC power supply in the lower section of the MAGNUM. There are two types of stepper motor drivers, a 24Vdc type (part no. 5601525) mounted in the Magnum with serial numbers below 68, and a 36Vdc type (part no. 5803356) mounted in Magnums with serial numbers above 68. These two types are not compatible! On the driver the current limiter can be set for one or two hex switches: Driver type 5601525 should be set for B. Driver type 5803356 has two current limiters. The default setup for these is not the same for Magnum and Mercury:
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Magnum Mercury Current limiter 1 (divi step / exposure) Current limiter 2 (quarter step / rapid traverse) A C 7 9
The current limiter should be set as low as possible due to the heat development in the driver and, especially, due to the exposure quality. Also it should be set so high that the stepper motor never stops. Current limiter 1 is nearest the LEDs (see figure 5.2.2.1.b. See chapter 2.3.3.2 for further information on carriage speed and step delay.
5.2.2.1. SPDM Module
On 36V drivers (5803356) it is possible to install an SPDM module (introduced in Production in December 1996). The purpose of Serial/Parallel Driver Module (SPDM) is to optimize the current to the spindle motor on Magnum/Mercur in the individual sequences run during film exposure. The SPDM module is mounted between the PGM and the driver on the 25-pole plug for cable 105.
Figure 5.2.2.1.a.
The module should be activated in the configuration program Version Dependent Machine Functions, and the power values
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of the individual steps in the exposure are keyed in in Change Carriage Constants. This requires as a minimum Software 6.03. Note: As the values for the current to the spindle motor in systems with SPDM are given via the control PC, the two current limiters should be set to 0.
Figure 5.2.2.1.b.
5.2.2.2. Replacing the Stepper Motor Driver
1.
Open the upper left and right door of the MAGNUM, observe that the spinner stops, remove the lower front plate of the cabinet, and locate the spindle driver next to the DC power supply. Unplug the DC power for the stepper motor driver first, and next unplug the rest of the connectors. Loosen the stepper motor driver from the fixing brackets, remove it and install the new stepper motor driver.
2.
3.
Note: Remember to check the current setting on the stepper motor driver before installing it into Magnum/ Mercury. Correct position is seen on the previous page. (The driver is set to Magnum default which this is extra important when replacing it in Mercury). The current selector can be accessed through a hole in the driver box. 4. Plug in the connectors, first the signal cables, and then the DC power connection. PURUP PREPRESS A/S
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5.
Mount the front plate on the MAGNUM cabinet, and close the cabinet doors. Select STATUS/FILM PLACEMENT/FIND & EJECT FILM, to make a clean up. Load the service program, and make a function test of the carriage, see also item 2.1.2.10. in chapter 2 of the MAGNUM service manual. Finish the operation.
6.
7.
8.
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6.
Cabinet
When we refer to dimensional stability and precision in the MAGNUM, the end result on the film is caused by a number of factors and thus also a number of specified errors:
6.1. Climate Control

The medium supplier's production tolerances. The physical conditions inside the MAGNUM, i.e. temperature and humidity. Inaccuracies of bit-map data processing, mechanics options and electronics. The influence of the developer on the film.
Below we shall concentrate on conditions regarding film temperature and influence of humidity before and during exposure.
6.1.1. Why Climate Control?
In order to comply with the specified precision requirements, it is necessary to control the parameters temperature and humidity very accurately. This problem can be solved in two ways: MAGNUM without climate control unit. The environment (air), in which the machine is placed, should be climatically controlled. MAGNUM with climate control unit. The machine itself controls temperature and humidity in the exposure area. This also means that the machine can be placed in normal office environment.
6.1.2. Control Range
The Magnum Climate Control is designed to regulate the environment between 20 and 80% RH and 15 and 28 degrees C. As is shown on the IX diagram on the following page, there is a critical area in which has high temperature and high humidity. Area II can be controlled by the unit. SERVICE MANUAL
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6.1.3. How does a Climate Control Unit function?
The main function of a traditional cooling unit is as follows:
Compressor Unit with Air-Cooled Condenser and Air-Cooler a. b. c. d. e. f. g. Condenser Compressor Evaporator Cooler Part Air Cooler (c+f) Fan Capillary tubes (normally only used for small units)
Fan (f) (inject) leads climatized air into the exposure area in which the air is influenced by:

Excess heat from control modules, motors, etc. Emission of heat from surroundings through the insulating material of the cabinet. Air exchange to air outside the MAGNUM due to leakages in the cabinet.
Air is sucked from the exposure area into the top of the climate control unit. Here air temperature and humidity are measured, and the controls determine whether to correct temperature and humidity.
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Air passes the evaporator (c), i.e. the cooling surface. The evaporator temperature is set by the control input to the cooling compressor (b). After the evaporator a heating element is placed in case heat is required, i.e. the cooling compressor is blocked. Close to this heating element the humidifier is placed. The purpose of the humidifier is to add water to the air if the control records a humidity lower that permitted. The evaporator has a double function as it is possible to dehumidify air as well as to cool the air as described above. This requires that the surface temperature of the evaporator has decreased to approx. 8-10 oC, upon which water is condensed. This forced cooling will of cause affect air temperature, and the heating element will then outbalance the excess cooling automatically. The evaporator is connected to the cooling compressor (b) via copper tubes (g), making a closed compressor-driven circulating circuit. The copper tubes contain a refrigerant, i.e. an energy transporter, the type of which is determined by the purpose. The energy which is collected by the evaporator is emitted to the condenser (a). A fan (f) leads air from the bottom of the MAGNUM past the compressor and condenser and out through the top rear side of the ImageMaker cabinet. In the Nilan Climate Control Unit the refrigerant type R-22, Difluormonochlormethan or R-134a, is used. Below is explained how a cooling circuit functions:
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The illustration shows as follows: 1 ->2: The refrigerant, here in gas form, is compressed by the compressor to high pressure, this is thus the pressure side in the circuit. The refrigerant flows into the condenser. The high pressure and the cooling of the surroundings, means, however, that the refrigerant starts to condense. When a fluid goes from gas to liquid it means that the fluid goes to a lower state of energy, i.e. the liquid and the cooling process emit heat. Immediately before the expansion valve the refrigerant is entirely in liquid form. The valve permits the refrigerant to expand, i.e. the pressure falls. This is the low pressure side, called the suction side. The liquid refrigerant now flows to the evaporator. The evaporator absorbs heat from the surroundings, i.e. it cools the air. The absorbed heat brings the refrigerant to the boiling point, i.e. it evaporates.
2:
3 -> 4:
4:
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6.1.4. Optimal Operation of Climate Control Unit
As even small changes in temperature and humidity can cause the films to expand or contract, it is vital to keep temperature and humidity at constant levels during production in order to ensure material stability and consistent output.
Climate Control Unit
Offline indicator
Release button
The factory setting of the MAGNUM Climate Control unit is: Temperature Humidity 22C / 72F 44% RH
The Climate Control system is located in a separate unit which is "plugged on" to the right side of the MAGNUM after the right doors of the MAGNUM are removed. The Climate Control system does not have a separate On/Off button or a separate power cord, as it is powered from the MAGNUM. The Climate Control unit is constantly in operation - even if the MAGNUM is shut down using the Power Button or the "Turn Off" command in the Exit menu. The only way to switch off the Climate Control unit is by means of the Main switch on the MAGNUM. If the normal operation of the Climate Control system is interrupted for example, if you open the door of the unit
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during operation or the Climate Control Unit is not in correct position - a small red lamp at upper right corner of the unit will glow to indicate that the system now is "off-line". As soon as the cause of interruption is removed, the Climate Control unit will resume normal operation automatically. Two displays on the Climate Control unit allow you to check the current temperature and humidity inside the machine. The displays are located behind the lower door on the right side of the Climate Control unit. The current temperature and humidity is also shown in the Environment" dialogue box on the Control PC. The allowed range for temperature and humidity level are:
Allowed range Temperature Humidity 20 -24C / 68 - 75F 34 - 54% RH
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The Climate Control unit requires very little attention from the operator as it is supplied with water from a tap; likewise any surplus water that is condensed inside the system is led to either a drain or an overflow container. If the water supply by accident is switched off, the water level in the climate control system becomes too low and the message "Climate control water level low" appears in the Message box. Note If the Climate Control unit is moved to another location, make sure to empty the water container and always keep the unit in an upright position.
6.1.5. General Maintenance
To avoid a concentration of chemicals in the water tank to increase to a level where it becomes corrosive to the tank and heating element, it is advisable to totally empty and clean the water tank at intervals of approx. 1 months or less.
6.1.5.1. Climate Control Cleaning Filters
Three cleaning filters prevent dust and small particles from entering the MAGNUM and the Climate Control unit.
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The filters for the Climate Control unit are located: 1) 2) 3) in the lower left door of the MAGNUM at the bottom of the Climate Control unit in the lower door of Climate Control unit
The warning "Dust filter clogged" appears on the PC when the cleaning filters must be replaced. Each filter consists of a fibre filter mat inside a metal filter frame. New fibre filter mats are available from Purup Prepress. Follow these steps to change the filter mats: Note Switch off the ImageMaker MAGNUM before you start replacing the filter mats.
Filters in doors: 1. Open the lower left door of the MAGNUM and the lower door of the Climate Control unit. Slide the filter frame upwards until the lower edge of the filter frame is released. Remove the filter frame by gently pulling its lower edge down and out until the filter frame is no longer seated in the door. Replace the filter mat if it is clogged. Reverse the above procedure for reinstallation (steps 1 through 4).
2.
3.
4. 5.
Filter at bottom of Climate Control Unit: 1. Push the release button on the Climate Control unit and swing it open to get access to the cleaning filter. Release the filter frame by turning the fasteners until the filter frame is released.
2.
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3. 4. 5.
Remove the filter frame by lifting it up. Replace the fibre filter mat if it is opaque and clogged. Reverse the above procedure for reinstallation (steps 1 through 4).
6.1.6. Cooling System
(only relevant for ImageMaker MAGNUM models without a Climate Control unit) The cooling system is a ventilation system designed to keep down the temperature inside the MAGNUM. Air intakes take in air to cool off electrical and mechanical modules inside the machine. The warm air is exhausted via an exhaust slot located at the back of the machine. Make sure not to restrict the air flow by placing objects too close to the MAGNUM. In addition, the cooling system maintains a slightly higher air pressure inside the machine which prevents dust and small particles from entering the MAGNUM.
6.1.6.1. Cooling System Cleaning Filters
Two cleaning filters for the Cooling system are located inside the lower left and right side doors of the MAGNUM. The warning "Dust filter clogged" appears on the PC when the cleaning filter must be replaced. Each filter consists of a fibre filter mat inside a metal filter frame. New fibre filter mats are available from Purup-Eskofot.
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1) 2)
in the lower left door of the MAGNUM in the lower right door of the MAGNUM
Follow these steps to change the filter mats: Note Switch off the ImageMaker MAGNUM before you start replacing the filter mats. Open the lower left door of the MAGNUM and the lower door of the Climate Control unit. Slide the filter frame upwards until the lower edge of the filter frame is released. Remove the filter frame by gently pulling its lower edge down and out until the filter frame is no longer seated in the door. Replace the filter mat if it is opaque and clogged. Reverse the above procedure for reinstallation (steps 1 through 4).
1.
2.
3.
4. 5.
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6.2. Climate Control 6.2.1. Specifications
6.2.1.1. Temperature/ Humidity Coherence
As the film roll is packed at 20 degrees C and 50% RH which is equivalent to 7.3 g water/kg air, it is important to keep this relationship between temperature and humidity during exposure. To maintain 7.3 g water/kg air under different temperatures, the following physical coherence is given: Temperature Humidity %RH 37 39 41 44 47 50 53 56 60
C
25 24 23 22 21 20 19 18 17
The ideal situation
6.2.1.2. Reaction Time
The volume of the exposure chamber is app. 1 m. With the recirculation air-quantity at 240 m/h, the air-change time is app. 15 seconds.
6.2.1.3. Filter Watch
To check the filter condition, a filter watch is placed within the recirculated air. Operational mode: On/off Normal closed. Adjustable set point.
Adjustment of filter watch adjustable from the outside of the unit and preset to 0.8 bar.
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6.2.1.4. Electrical Interface
The interface to the Magnum for external monitoring is as follows:
6.2.2. Setting of PID Regulators
With the Climate Control Unit operating, the humidity regulator and temperature regulator should show present % RH and temperature oC. If the humidity regulator shows 0, it should be checked whether the 15 pole cable connector is connected correctly, as the display depends on a signal resistor in the cable. Start Programming:
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You can protect all functions, except for user settings, functions 1 to 3, against unintended setting by changing the position of the jumper behind the bottom front panel. (You may have to use a screwdriver to remove the panel).

Press "p". Two figures are displayed separated by a period.
First figure is setting value. The last figure is parameter according to enclosed regulation table. Press *. Changes between the two values and the figure flashing can be increased or decreased with the keys
" and !.
Note: First set parameters 16 to 24. Exit program mode. Return to program mode and set the remaining values. By adjustment of parameter 24 (temp area): Press
Press * to show are (400) Press and hold *, press
! or "to change function number (--24) ! or "to change value.
In parameter 13 you go to parameter 38 after pressing "p" for 6 seconds.
6.2.2.1. Humidity Control Settings
If left number on the control is blinking (0), it means that no sensor type has been chosen. Read in the value 11 in parameter 16. SP1: Relay for dehumidifying: SP2: Relay for humidifying: Green diode Red diode
Selecting Reference Humidity (Normal = 44% RH)
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If % RH: 44 is wanted, press and hold * and use display shows 44% RH, and let go. Set value 0
! or " until
Parameter Text/function/absolute value 0 Operation request: Normal. 1= Autotune (AT) 2= Autotune fine (PT)
0 -2
1 2 Neutral zone (N.Z.) humidifying and dehumidifying: 2 %. >0= Overlap <0= N.Z. Alarm/relay hold request: no Cycle-time dehumidifying: 30 sec. Proportional band dehumidifying: 0,5% of configuration area (CR) Derative band dehumidifying: Out DAC access control: AT values Integrating-time dehumidifying: Out Offset calibration of read-out: Value can change. Cycle time humidifying: on/off Hysteresis humidifying: 5% Alarm for pipe break: Out PURUP PREPRESS A/S
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"0"
10
6 0 SERVICE MANUAL
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PAGE 6.2.5
0 0 0 11 0 0 7 1
13 14 15 16 17 18 19 20
Function channel not used Function channel not used Reset of read-in data: Normal Sensor choice: 0-20 mV input Neg. read-out: no. Decimal read-out: no Both relay outputs active: yes When pipe breaks: Dehumidifying ceases When sensor breaks: Humidifying ceases Unit: %RH Displays actual S.W. version of control unit Set point max. value (CR): %RH
21
0 -
22 23
50
24
Access to Special (Hidden) Functions Press: Press: Press and hold for 6 seconds: p (and let go) and the display shows 0.0 (and let go) and the display shows 0.13 until display shows 0.38
"
*
When display changes from 0.13 to 0.38, step with function 26.
" to
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26
Max. dehumidifying connected: 100% Max. humidifying connected: 100% Inverted dehumidifying relay: yes Inverted LED function: yes Inverted humidifying relay: yes Inverted LED function: yes Indicator sensitivity: low Display sensitivity: low Function channel not used Sensor area adjustment: 0 Alarm/relay hold request:: no
27
28
1 1
29 30
1 2 2 0 0 0
31 32 33 34 35 36 37
38
Monitoring activated: no. (Monitoring: 39, 40, 41, 42) Note that functional number 38 appears as first parameter when "special functions" is chosen.
39
Read-out of variance in i % RH. Read-out of max. measured % RH. Read-out of min. measured % RH. PURUP PREPRESS A/S
40
41
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PAGE 6.2.7
42
Read-out of percentage dehumidifying
6.2.2.2. Temperature Control Settings
If left number on the control is flashing (0) it means that no sensor type has been chosen. Read in the value 9 in parameter 16. SP1: Relay for cooling: SP2: Relay for heating: Green diode. Red diode.
Setting Reference Temperature (Normal = 22oor 71oF): If 22 C : is required, press and hold * and use display shows 22 C, and let go. If 71 F : is required, press and hold * and use display shows 71 F, and let go. Set value 0
! or " until ! or " until
Parameter Text/function/absolute value 0 Operation request: 0= Normal. 1= Autotune (AT) 2= Autotune fine (PT)
0 0 0 4 2
1 2 3 4 5 Alarm/relay hold request: no. Cycle-time cooling: 30 sec. Proportional band cooling: 1% Derivative band cooling: 20 sec. DAC access control: 1.5 x proportional band
12
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Integrating time cooling: 0.2 min. Calibration of read-out. Value can change. (If F, the figure is multiplied by 1.8) Cycle-time heating: on/off. Hysteresis heating: 0.25 % Alarm for pipe break (time): Out Function channel not used Function channel not used Reset of read-in data: Normal Sensor choice: PT 100 input. Neg. read-out: no Decimal read-out: no. Both relay outputs active: yes. In case of sensor break: Cooling ceases In case of sensor break: Heating ceases 0=C 1=F
"0"
0 1 0
10 11 12
0 0 0 9 0 0 7 1
13 14 15 16 17 18 19 20
21
0/1
22
If temperature mode is changed, check control functions 9, 22, and 24 and select the desired reference temperature (oC or oF) 23 25 24 SW. version Set point max. value: 25 C (If F then 77 F ) PURUP PREPRESS A/S
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PAGE 6.2.9
Access to Special Functions Press: Press: Press and hold: p
"
When display changes from 0.13 to 0.38, step with t to function number 26. 0 0 1 1 1 1 0 0 26 27 28 29 30 31 32 33 34 0 0 35 36 37 0 38 Monitoring activated: no. (Monitoring: 39, 40, 41, 42) Sensor area adjustment: % Alarm/relay hold request: no. Max. cooling connected: 100% Max. heating connected: 100% Inverted cooling relay: yes Inverted LED function: yes Inverted heating relay: yes Inverted LED function: yes Indicator sensitivity: normal Display sensitivity: normal
Note that function number 38 appears as first parameter when "special functions" is chosen. 39 Read-out of variance in C
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40
Read-out of max. measured C Read-out of min. measured C Read-out of percentage cooling
41
42
6.2.3. Error messages
Application error: Code EE1 EE2 EE3 Meaning Sensor burned off RTD/PT100 short-circuit LBA wirebreak alarm
Autotune AT/PT cycle alarm Autotune process failed EE5 EE6 EE7 Timeout Limited exceeded Cannot run Autotune
Software error EE8 EE9 Press Calibration error (replace regulator if repeated) System error (replace regulator if repeated)
" and ! simultaneously to reset the error.
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PAGE 6.3.1
6.3. Troubleshooting
The function of the climate control unit can be divided into two main sections: 1. An electrical system in which service personnel trained by Purup-Eskofot can troubleshoot or replace parts. A refrigeration system. This system can only be serviced by technicians trained in refrigeration techniques and not by Purup-Eskofot personnel.
2.
The following section should enable PE technicians to identify electrical problems and remedy them. It should also be possible to verify the function of the entire electrical system to demonstrate if a source of error can be located in the refrigeration system. This chapter first has a general section followed by a section for each part function.
Numbers in parentheses refer to the diagram page 6.3.15.
General Check Procedure The following describes check procedures that should be complied with if the entire system should be functional. If the cooling system is to run outside the cabinet, a dummy jumper should be mounted as shown below. Remember to activate the door switch (37)
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1.
Check the mains power inlet. If there is no power, check the AC box. Check the power from the transformer. Measure the power on the terminal block in the electrical box
2.
Check 115Vac, 230Vac and 24Vac. If you find an error, you should replace the transformer.
3. 4.
Check that the autofuse (51) has not disconnected. Check 24Vac on the system, e.g. point 32 and 33 on the circuit board. If there is no 24Vac, check F4 (47) and F5 (48). Check whether the compressor is running. This can be checked by touching the surface of the compressor with your hand. (Demount the electronics box for access). If the compressor is not running, there is a problem in the refrigerating circuit. Check that the circulation fan condenser (15) is running.
5.
6.
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PAGE 6.3.3
If it is not running, check F2 (49). Note that a defect capacitor (36) can cause that the motor runs at reduced speed.
7.
With the safety system active (remember door switch(37)), check that there is voltage on A1 and A2 on Relay K2 (43). If the relay is active and there is not 24V in the safety _ loop, replace the relay. Check that the fan in the ImageMaker is running. Note that the fan runs at reduced speed if the capacitor is defect. Check setup of the two PID regulators in section 6.2
8.
9.
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6.3.1. Cooling Function
Functional Description The PT100 sensor (32) reports heat. The PID regulator (27) breaks switch set 10 and 11 and the bypass valve (4) closes. The entire cooling circuit is thus active. The cold air is circulated though the exposure chamber by the ImageMaker fan box.
Cooling Function Check of Function Set the PID regulator below present temperature with the safety system active (remember to activate the door switch(37)), thus closing the bypass valve (4). There must not be 24V over the valve.
Check of 24V on bypass valve
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PAGE 6.3.5
Refrigerant To check that the amount of refrigerant is OK and that it is not contaminated, the sight glass (6) should be inspected. Turn off the climate control unit and wait for 1 minute. Turn on the climate control unit and check that are bubbles are visible in the sight glass (6). The bubbles should disappear after max. 5 minutes. If no bubbles are visible, the cooling circuit is empty. If the bubbles remain visible, the amount of refrigerant is either too low or the the refrigerant is contaminated. The colour of the dot in the centre of the sight glass indicates whether the refrigerant is contaminated with water. Normal condition is green = dry. Check that evaporator (1) cools off. Reset the PID to the wanted temperature. If the evaporator does not cool of, please observe the following: Defrosting thermostat (30) should be disconnected (switch set 3 and 6 disconnected). Dismount one of the wires.
Check of defrost thermostat Bypass valve (4) is functional (cooling circuit active when there is no 24V on the valve). PT100 sensor is functional. PID regulator is correct set and functional.
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Verify defect PID or PT100 sensor by replacing the units. If these conditions are OK and the cooling function still does not work, there is a problem in the cooling circuit.
6.3.2. Heating Function
Functional Description The PT100 sensor (32) reports low temperature. The bypass valve (4) is opened so that the cooling system is neutralized. The PID regulator (27) gives voltages to the coil on relay K2a (44) and the switch set 3 to 5 closes thus giving voltage to the heating element (34). The hot air is circulated through the exposure chamber by the ImageMaker fan box.
Heating Function Check of Function With the safety system active (door switch) set the PID above present temperature which connects 700W heating element (34). Thermostat: Check that approx. 230 Vac appears on both the thermostat (25) connectors. Turn down the thermostat setting and check that the voltage disappears on one of the connectors. Heating Element: Switch off AC. Remove the wire with no voltage from the thermostat (25) and connect an Ohmmeter between this wire and N on the SERVICE MANUAL PURUP PREPRESS A/S
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PAGE 6.3.7
terminal block. With a functional heating element measure approx. 77 Ohm. Reconnect the wire, reset the thermostat to 40 degrees C and reset PID to original setting. Please observe: F3 is OK Thermofuse (39) is OK. Check that there is passage. The thermostat (25) measures maximum 40 degrees Celsius (passage) Heating element is OK (approx. 77 Ohms) The PID regulator is correctly set and functional. The PT 100 sensor is functional Relay K2a (44) is functional
Defect PID or PT100 sensor is verified by replacing the units.
6.3.3. Dehumidifying
Functional Description The humidity sensor (33) reports high humidity. The PID regulator (26) disconnects the set of switches 10 and 11, the bypass valve closes and the full cooling circuit is thus active. The cold evaporator results in condensation of air humidity. Note that the dehumidifying process is a partially cooling process. If dehumidifying is wanted without cooling, the heating element (34) is active to compensate for the cooling.
Dehumidifying PURUP PREPRESS A/S SERVICE MANUAL
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Check of Function Set the PID regulator below present air humidity. Check the cooling function as described in section 6.3.2. Please observe the following Same conditions as when cooling The humidity sensor is functional The PID regulator is correctly set and functional.
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6.3.4. Humidifying
Functional Description The humidity sensor (33) reports low humidity. The PID regulator (26) connects the set of switches 6 and 7. This gives voltage to the coil on relay K3 (45) , thus connecting set of switches 3,5 and giving voltage to the heating element (19) and fan (16). This causes transport of air over the surface of the water reservoir water bath. The water surface is forced to supply water vapour to the air. The heater (19) is started to ensure sufficient humidity.
Humidifying Check of Function With the safety system active (remember to activate the door switch (37)), set the PID regulator above present air humidity. Check that the fan (16) is running and that the air gate on top of the water reservoir valve (18) opens. Heating Element: Dismount cover to the junction box (12) and identify the heating element connections. Dismount the wires on the heating element and connect an Ohmmeter to the element terminals. With a functional heating element, measure approx. 208 Ohm. Reconnect the wires and remount the cover to the junction box. PURUP PREPRESS A/S SERVICE MANUAL
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Reset the PID to the wanted humidity. Please observe the following F2 is OK There is water in the water reservoir (see the section on automatic water feed). The PID regulator is correctly set and functional. K3 (45) is functional. The humidity sensor is functional.
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PAGE 6.3.11
6.3.5. Replacement of Parts
Replacement of Motor Loosen two screws and guide out the motor at the bottom
Replacement of Regulator Dismount the connector by pressing the two nobs.
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Tilt out the two locking pins and pull out the PID regulator through the metal plate.
Position of Sensors To access the PT100 and the humidity sensor, you should dismount the top. Please note that the top is sealed with silicone and can be quite tight. Remember to tighten the top with silicone when you remount it.
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6.3.6. Automatic Water Feed
Functional Description The automatic water feed functions as follows: A timing circuit gives signal to a 24V DC relay (42 Relay Water valve) for 5/10 seconds every minute when required, i.e. water is only fed when water level is low and water is required and only for a brief period of time. Check of Function Water level is read by a read switch (17 water level sensor), and the function can thus easily be checked by a ohmmeter. Low level = closed (~5$), high level = open ( $). Please note that the float should be positioned correctly as the function will otherwise be inverted.
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PAGE 6.3.15
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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
Evaporator (1361047) Condensed water tray (1655002) Thermostatic expansion valve (3200006) Solenoid valve - Bypass (2510020) Junction box defrosting thermostat Sight glass Dry-type filter element (1481186) Receiver Pressure switch (3200007) Service valve (3200008) Compressor (3130012) Junction box Condenser (1361048) Switch 115V - 0 - 230V Circulation fan condenser (3140035) Circulation fan water evaporation (3140036) Water level sensor (complete) (3020025) Butterfly valve for air humidification Heating element water reservoir 250W (3800000) Filter guard (3200002) Printed circuit board (5601820) Electricity tag block Transformer 115V / 160V / 230V 24V (3110031) Water reservoir (5803559) Thermostat for heating element in inject ari 0 - 40 C (3200011) PID humidity regulator (3150006) PID temperature regulator (3150006) Computer slot Plug for main supply Defrosting thermostat (3200009) Diode
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
PT 100 sensor (3020029) Humidity sensor (3200003) Heating element in inject air 700W (3800001) Water valve (3200004) Capacitor 2 F (2220043) Switch, off line (3010110) Plug, heating element water reservoir Temperature limiter 72 C air (3200012) Klixon 50 C Water supply and water outlet box Relay water valve 24V DC K1 (3090042) Relay off line 24V AC K2 (3090041) Relay heating element air 24V AC K2a (3090043) Relay humidification K3 (3090043) Computer slot Fuse 1.25A (Schurter order no. 0034.3118 ( 2810080) Fuse 1.25A (Schurter order no. 0034.3118 ( 2810070) Fuse 3.25A (Schurter order no. 0034.3999 ( 2810069) Fuse 3.25A (Schurter order no. 0034.3999 ( 2810069) Circuit breaker 16A Capacitor compressor (2220042)
Top cover for water tank (reservoir) complete (5803159) Socket for relay 2-P (42, 44, 45) (3090039) Socket for relay 4-P (43) (3090040)
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PURUP IMAGEMAKER MAGNUM VACUUM SYSTEM
PAGE 6.4.1
6.4. Vacuum System
The purpose of the vacuum system is mainly to keep the medium material steady in the drum during exposure. If the MAGNUM has the built-in optional register system, the vacuum system also ensures that the medium is kept steady before activation of the register punches, and finally the vacuum system ensures that the register waste bits are removed from the drum during unloading and put into an register waste container. The vacuum system consists of the following main items: Vacuum System Vacuum Valve Flexible Hoses Vacuum Pump Various Fittings Waste Container Vacuum Sensor
Furthermore, the vacuum system interacts with the vacuum manifold and vacuum grooves on the drum surface and the register waste grove. The air flow in the vacuum system is designed to have an optimal vacuum in all positions of the drum.
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Figure 6.4.1
Figure 6.4.1 below shows the airflow in the vacuum system 6.4.2. Position Numbers TBD
6.4.3. Vacuum Sequence
Below is a description of the vacuum sequence during exposure.

Medium load started. Start vacuum pump, if not already running. Turn vacuum valve to manifold position Register pins down. Exposure. Reverse carriage. Medium unload started. Turn vacuum valve to register groove position (valve port 1 and 3 connected). Turn vacuum valve to free air position (valve port 1 and 4 connected).
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6.4.4. Vacuum System Service
According to the spare part list the following items can be serviced.

Vacuum valve complete. DC motor. Vacuum sensor, drum. Hall element type 3.
6.4.4.1. Replacing the Vacuum Valve
1.
Power down the MAGNUM, open the lower left and right door, and dismount the lower front plate in order to access the vacuum system. Disconnect DC motor connector, Hall A and B connectors, and all air hoses from the vacuum valve. Unscrew the fix screws for the vacuum valve and lift it out. Mount the new vacuum valve and fix it to the cabinet. Connect DC motor connector, Hall A and B connectors, and all air hoses for the vacuum valve. Mount the lower front plate, close the lower left and right door, power up the MAGNUM, and observe that the function test runs successfully. Make a backup of the machine configuration and parameters, and finish the operation.
2.
3.
4. 5.
6.
7.
6.4.4.2. Replacing the DC Motor
1.
Set the MAGNUM off-line, open the upper and lower left door of the MAGNUM and observe that security errors are displayed on the PC monitor. The 24 Vdc should now be switched off. Unplug the connector for the DC motor, unscrew the four fix screws fixing the DC motor onto the gear box, and lift it away.
2.
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3.
Mount the new DC motor, fix it to the gear box with the four fix screws, and remount the DC motor connector. Close the upper and lower left door of the ImageMaker and set the MAGNUM on-line. The MAGNUM will make a clean up and be ready for exposure. Note: If necessary, load the service program and make a function test of the vacuum valve.
4.
5.
Make a backup of the machine configuration and parameters, and finish the operation.
6.4.4.3. Replacing the Vacuum Sensor
1.
Set the MAGNUM off-line, open the upper left and right door of the MAGNUM and observe that security errors are displayed on the PC monitor. The 24 Vdc should now be switched off. Demount the upper front cabinet plate, loosen the control module plate, and fold it down in order to get access to the vacuum sensor placed on the drum. Disconnect the sensor plug, unscrew the two fix screws, unplug the plastic hose and remove the vacuum sensor. Mount the new vacuum sensor by plugging on the plastic hose and signal connector and fix it with the two screws. Fold up the control module plate, mount the upper front cabinet plate, close the upper left and right door of the MAGNUM, and set the ImageMaker on-line. The MAGNUM will make a clean up and be ready for exposure. Note: If necessary, load the service program and make a function test of the vacuum system.
2.
3.
4.
5.
5.
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6.4.4.4. Replacing the Hall Element
1.
Set the MAGNUM off-line, open the upper and lower left door of the MAGNUM and observe that security errors are displayed on the PC monitor. The 24 Vdc should now be switched off. Unplug the connector for the Hall element (A or B), loosen the three fix screws for the vacuum valve end cover, and let it hang downwards. Note: The rotating valve rod might fall out so be ready to catch it!
2.
3.
Loosen the fix screw fixing the Hall element into the vacuum valve housing and pull it out. Mount the new Hall element into the vacuum valve housing, fix it with the fix screw and remount the rotating valve rod and the end cover. Plug in the Hall element connector, close the upper and lower left door of the MAGNUM and set the MAGNUM on-line. The MAGNUM will make a clean up and be ready for exposure. Note: If necessary, load the service program and make a function test of the vacuum valve.
4.
5.
5.
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PURUP IMAGEMAKER MAGNUM TABLE OF CONTENTS
PAGE C.7.1
7 Technical Notes
No. 1 2 3 4 5 6 7 8 9 10 11 12 Description Blown Fuses in Climate Control Cutting Motor not Rotating New Carriage Motor Driver New Fuse in Safety Loop Sporadic Errors in Vacuum System Load Problems with Polyester Plates Optimization of Film Handling Chemicals Sucked into the Magnum Software Versions and Fixes Suppression of Warnings Carriage Errors FCO Status List Date 960502 960502 960502 960502 960905 960905 961121 961121 970520 961205 970520 970520
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PURUP IMAGEMAKER MAGNUM TECHNICAL NOTE NO. 1
Blown Fuses in Climate Control
There have been problems with blown fuses in the climate control unit for the Magnum causing ice in the CCU. The two fuses under the PID panels are 1A fuses. You can replace them with 1.25A T fuses. All air condition units with revision C, S/N higher than 220124xx will have 1.25A fuse mounted from the supplier Nilan. Best regards Systems Support
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Cutting Motor not Rotating
From some installations we have reports of error 1547 Cutting motor not rotating. This error is caused by missing encoder signals from the cutter encoder. There may be more causes for this: 1. The cutter belt drive wheel is slightly loose on the motor shaft and slipping, therefore the encoder loses steps. Tighten the screws on both left and right wheels. Friction in the cutter system causes the cutter to start slowly and/or change speed. A remedy for this is to adjust control parameter 308 and 309: Set 308 Delay for enabling to 1000 (default 500) Set 309 Delay for encoder test to 40 (default 20) On Magnums up to SN #49 the axle was not fixed to the bearing pedestal. Therefore, axial movement may damage the encoder by internal mechanical friction.
2.
3.
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To solve this problem two snap rings should be mounted in position 3 as follows: Dismount the bearing pedestal by dismounting the holders position 1 and 2. Pull the left part, position 1, out of the axle. Mount a snap ring (Purup no. 1332057) up against the axle flange.
Remount the left part, position 1. Push it up against the snap ring. Mount the second snap ring on the outer side.
96 05 02
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Use a screwdriver to push the snap ring fully home. Remount the bearing pedestal, position 1 and 2. Note: Always have an extra encoder when you do this replacement to avoid production stop due to a damaged encoder.
Best regards Systems Support
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New Carriage Motor Driver
From ImageMaker Magnum serial number A 068 inclusive, we have installed a new motor driver for the carriage stepper motor and changed various other parts. The driver will increase the performance of the Magnum by cutting off approximately 20% of the carriage fast-step travel time. The new driver is NOT backwards compatible and will NOT be offered as an upgrade. In combination with this upgrade more items have been changed. The following list shows the NEW items and their part numbers. PGM Connector board Stepper motor driver (36 Vac) Power supply 24 VDC Distribution board AC Box complete 5803135 rev. B 5803356 3600068 5601788 rev. B 5803317 rev. B
There are also changes to the configuration setup: 1. Machine configuration, Version dependant Machine functions: Carriage fast mode = "ON" Hall encoder = "ON" (If this option is present in the menu.) Machine constants, Carriage constants: Max. Speed = "45" Single step delay = "6" to "10" (Start with value "6". If carriage errors, increase until errors disappear) The new driver has two binary, rotary switches to control the stepper motor current. The bottom switch controls current during exposure and is set to position "A". The upper switch controls current during fast step and is set to position "C".
2.
3.
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The position of the switch is indicated by an arrow-shaped slot in the centre of the switch. Best regards Systems Support
96 05 02
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New Fuse in Safety Loop
We have introduced a fuse in the safety loop on the Magnum as the PCB on the PGU connector board can burn off due to short-circuits between the +24 VDC in the safety circuit and ground. The fuse is mounted in a closed fuse carrier at the DC distribution board placed behind the bottom left door in the Magnum and it should be mounted on machines with serial numbers below 55. This is done by cutting the wire position J2 pin 5 on DC distribution board (5601788). The fuse carrier has screw terminals so all you have to do is to remove the insulation at the wire ends and mount the fuse carrier.
Spare part numbers are: T 250 mA Fuse Fuse carrier 2810068 2820012
We recommend that you mount the fuse carrier before you start operations that include the safety loop (e.g. carriage end stops). Otherwise, you can mount it in connection with another service call. Best regards Systems Support
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Sporadic Errors in Vacuum System

Problem Sporadic errors reported by the vacuum system, e.g. 7437 Vacuum valve time out. The vacuum valve motor is driven by motor driver C2 which is a weak motor driver. Differences in the mechanical friction in the valve may therefore in some cases cause the abovementioned timeout problems. It is possible to move the vacuum valve motor from the existing (weak) motor driver C2 to the stronger motor driver B. Move the vacuum valve motor cable connections on the SCM6 connector board: J7 pin 2 (C12+) to J6 pin 4 (B+) J7 pin 1 (C2-) to J6 pin 3 (B-)
Cause
Solution
Set item 10 Vacuum valve motor driver B active (+) in the version dependant machine constants in the configuration program (only possible in SW 6.01 and later). Other Too much mechanical friction in the valve may be caused by dirt or too much grease in the valve. Demount the valve and clean the brass core. Apply a thin layer of grease. Best regards Systems Support
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Load Problems with Polyester Plates Problem We have had reports of various load problems especially when running certain types of polyester plates. The medium is not detected by IR1 during load (eg. error 1277 and the film is rolled back into the magazine), or the medium is sporadically loaded too far. There may also be problems with finding the film during clean-up and ordinary production. The cause of the problems is that in the Magnum the film is detected in the drum by an IR sensor (IR1) and not by a US sensor as in the Maestro. The IR sensor measures the reflection from the medium, and different surfaces may therefore have different trig level. The solution of the problem is to change the sensitivity of the IR sensor by adjusting the trig level: Problems during find film ( static check): Reduce IR1_TRIG to e.g. 5 (default = 10). IR1_TRIG is SCM parameter 62. Reduce IR1_DYNAMIC from 5 to e.g. 2 or 3. IR1_DYNAMIC is SCM parameter 63.
Cause
Solution
Errors during film load (dynamic check):
For load problems we recommend always to disable the encoders on roller and belt motor.
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Optimization of Film Handling

A few parameters can be changed to optimize film handling in the Magnum /Mercur. Note: Due to the fact that modified parameters are reset to the original values after installing a new SW-release, it is recommended that you make a note of the changes and reenter the values after SW-installation. SCM 83: SLOW_COUNT This parameter controls the length of the slow speed part of the film-to-processor transport sequence. The slow speed is activated to let the film enter the film processor correctly. If the film processor has a problem with gripping the film, this parameter may be increased (100 = appr. 50mm). SCM 110 - 117: HASP_XX These parameters control the film handling speeds, and the 0,1,2 appendix refers to the 3 handling speed settings (reduced, normal, high), respectively. HASP_IN is the loading speed, HASP_OUT is the transport speed in the conveyor when the film exits the Magnum/Mercur. If problems occur at one of the film handling speeds, it might help to modify the corresponding parameters. Increased values gives decreased speeds.
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96 11 21
Chemicals Sucked into the Magnum

In order to minimize the risk of chemicals sucked into the magnum/Mercur causing crystallisation and other chemical reactions (parts in the ImageMaker look corroded but might not be), you can use the following check list. Please note that these conditions are general but especially important in the combination Magnum/Mercur with climate control and connected to a HOPE processor (also known as ECHO GRAPHICS and CARNFELDT). Note: We recommend that you always install FCO#2 (4000126) on these machines.
CHECK LIST Magnum/Mercur: Regular cleaning of the filters (three). Processors in general: As the exhaust of the processor is the essential thing in this connection it is important to note that the exhaust of the processors is in operation always when there is liquid in the processor. This means that the processor is never switched off but only in stand by as the processor exhaust is thus kept active. Exhaust should be in operation 24 hours a day. If connected to a superior exhaust, it is important that they are constant in capacity. Note: If the exhaustion is not switched on, the lid on the vessels should be removed and the Magnum/Mercur switched off. HOPE processors in particular: Both bottom plates should be mounted correctly so that they are placed on the bottom frame with all four edges. There should be max. 6mm air round hoses. Is the 100 (4 inches) hose fixed to the fan at one end and to the rear side of the machine at the other end and is the hose without ruptures. 96 11 21
PURUP PREPRESS A/S
There must be max. 6 metres hose leading from the processor. Check that all cabinet plates are available and placed correctly - also the one side turned in towards Magnum/Mercur.
96 11 21
PURUP PREPRESS A/S
Software Versions and Fixes

This technical note gives a brief reference regarding software versions and fixes. Please note that error corrections from a fix are also included in the following versions (i.e. corrections from 6.01 fix 1 are included in 6.02). SW 6.01 From version 6.00 to 6.01 there were many important changes and error corrections. All installations must as a minimum run software 6.01. SW 601 fix 1 Correction of the problem with bitbus errors (e.g. 7690, 7710, 7730...). This error occurs in connection with fast PC types as e.g. Simens 4H. This fix (and following software versions) slows down communication between the motherboard and the BBM board. The bitbus speec between PC and ImageMaker is not affected. SW 6.02 Spinner does not automatically run 24000 rpm after a couple of hours shurt down but waits until something happens. A combination of Laser shutter and visible red laser diode is made possible. Thios combination is used in connection with HE-NE lasers. In Register offset all values are set to 0, and it is no longer possible to adjust the values. SW 6.02 fix 1 Correction of error 580 Hardware version error in connection with HE-NE laser configuration. SW 6.03 Correction regarding the problen that the PS-Link is disconfigured due to errors during test film as density film. Correction regarding sporadic bitbus warnings and Safe filmlength set to 0. Functions are added in connection with the SPDM module, and Magnums with this module should as a minimum run 6.03. PURUP PREPRESS A/S 97 05 20
A short-cut Shift F3" is introduced. It is possible to run one resolution per film or all resolution on the same power film.
SW 6.03 fix 1 Not released SW 6.03 fix 2 Not released SW 6.03 fix 3 This fix is developed to enhance the bitbus communication to different PC types. Programmable delay has been introduced in the configuration program. Best regards Systems Support
96 11 21
PURUP PREPRESS A/S
Suppression of Warnings
The following is a method to taylor which warnings you want to suppress when you have chosen the function Warnings off in Optional Machine Functions. Normally, we recommend that you choose Warnings off to suppress all warnings that do not require specific action. However, it may be an advantage that some warnings are displayed even if warnings have been disconnected. The list below shows some of the warnings that you may not want to suppress: 00585 00586 00596 00623 00657 00860 03605 03606 03607 03608 04116 06500 06501 06502 06503 07435 Filmprocessor temperature warning. Filmprocessor liquid level warning Received unknown command from workstation Waiting for film processor Magazine position error. Direct positioning PC was powered down without exiting program Spinnerspeed too high at 24000. RPM = Spinnerspeed too low at 24000. RPM = Spinnerspeed too high at 12000. RPM = Spinnerspeed too low at 12000. RPM = ARION laser getting worn out. Temperature in cylinder too low. T (C) = Temperature in cylinder too high. T (C) = Temperature in cylinder air too low. T (C) = Temperature in cylinder air too high. T (C) = Vacuum valve positioning conflict.
If you want that one or more warnings should not be suppressed, you can correct the list by a text editor, e.g. EDIT. The file to be corrected is C:\ELEF\ALARM\repsupp.def (on Maestro C:\z000\ALARM\repsupp.def). Best regards Systems Support
PURUP PREPRESS A/S
96 12 05
Carriage Errors
Problem: Carriage errors eg. 3846, 3881, 3891.... occur on machines with 36V driver. These errors primarily occur when starting the machine in the morning. If the known parameter adjustments (Single step delay and current limit setting) do not solve the problem, the motor frequency can be descreased, and thus the motor torque is increased. As the parameter Maximum carriage speed in kHz can only be decreased to 40 (default 45) in the configuration program, the following work around can be used. 1. 2. Exit toDOS Use the editor to change the value in the file C :\elef\config\machine.def. The value you need to change is 35 Maximum carriage speed in kHz.
Solution:
Please note that this work wround slightly decreases the performance during load/unload. Best regards Systems Support
PURUP PREPRESS A/S
97 20 05
FCO Status List

This Technical Note gives a brief reference regarding FCO kits and FCO status. FCO#1 Screen Quality (4000125, incl. FCO#2) Vibration dampers under drum Vacuum pump vibration damper Flare guides SPDM DC/DC converter Capacitor in modulator cable CCU vibration damper Sealing Kit (4000126) Reduces the amount of air being controlled by the CCU and thus reducing the risk of chemicals being sucked into the Magnum Filter Kit (4000127) Reduces the concentration of dust in the exposure area by optimizing the flow through existing air filters and filtrates the recirculated air.
FCO#2
FCO#3
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97 05 20
REV. B
PURUP IMAGEMAKER MAGNUM TABLE OF CONTENTS 8
PAGE C.8.1
Table of Contents
Page
8. Miscellaneous/Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.1 1. 2. The MAGNUM Register System, PIN-SAL-05-50 (non-controlled hard copy) Extracts from the Purup ImageMaker MAGNUM User's Guide
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REV. E
PURUP IMAGEMAKER MAGNUM SPARE PARTS
PAGE 9.1.1
9.
Spare Parts
LIST OF SPARE PARTS FOR PURUP IMAGEMAKER MAGNUM Valid as from 1-September-1997 There are three categories of spare parts: Category 1: Modules/parts of modules which can be replaced directly without any adjusting/changes of PC-Config, by applying ordinary hand tools, if necessary, with a short description/procedure. Category 2: Modules/parts of modules which when being replaced require adjustment/changing of PC-Config by using ordinary hand tools and therefore need a specific procedure. Category 3: Modules/parts of modules which when being replaced require a PIM special tools bag, apart from the application of ordinary hand tools and if necessary PC software. Therefore this requires a very specific procedure. ---------------------------------------------------------------------------------------------------------------
AC modul, 5803183S AC power box, MAGNUM. (sn >68) 5803317S AC power box, MAGNUM. (sn <68) Cabinet, 1341044 1372020 1372058 1434003 1481144 1618039 2840012 5801219 5801720 1372040 1372026 1372038 1372025 1619085
Rev/Type A B Rev/Type 084794 A1 STL 6000MD-131848 082678 A A 1722/863120 CARDIC 425850 C
Cnt. DK *** DK *** Cnt. DE *** DE DE *** DE DK *** DK *** DK *** DK *** DK
Gas spring 600N. Light seal (brush L=31cm), magazine. Light seal (brush L=91,8cm), magazien Gas spring 150N. Air filter, MAGNUM. Foot for MAGNUM. Bulb for operator lamp. Operator lamp complete Hall element type 5. (door) Light seal 3x6 mm Light seal 6x10 mm Light seal 6x6 mm Light seal 10x10 mm locking latch (upper film cover)
B Rev/Type C B 503169-1.Rev.A D 503169-3.Rev.A 503169-2.Rev.A C 501933-4
DK Cnt. DK *** DK DK DK DK DK DK US
Cables, ext., 5401535 Cable, ekstern PC power. 5401536 PIM/PC Bitbus. 5401537 FDDI Optic, 20m. 5401549 Cable 39 AC pow. 5401578 FDDI Optic, 50m. 5401660 FDDI Optic, 5m. 5401684 Cable 39 AC pow. 3900066 FDDI adaptor (connector)
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PAGE 9.1.2
REV. E
Rev/Type Climacontrol, 1341073 Gas spring, climate unit. LIFT -O-M 192872 1481143 Air filter, climate unit. MAGNUM. A 5803173S Climate unit. MAGNUM. D 3150006 PID regulator (Temp. Humidity) 5803159 Top cover for water tank (with level sensor and heat element). 3020025 Magnetic water level sensor Conveyor system, 1412021 Toothed belt, short. 1412022 Toothed belt, long. 1412025 Elastic flat belt, short. 1412026 Elastic flat velt, long. 1432130 Rubber roller. 5801720 Hall element type 5. (Mag. position) 5801722 UL sensor,trans./rec. 5801740 Motor for conveyor, complete. 5801742 Film snip sensor. 5801748 Film cut sensor Output slit assembly, 5801722 UL sensor,trans./rec. 5803237 Filmbuffer. Rev/Type 100XL037 140XL037 31,12"x0,56" 38,03"x0,56" B C D C D B Rev/Type D A
Cnt. DK *** DK *** DK ***
Cnt. JP *** JP *** US *** US *** DK *** DK DK DK DK DK Cnt. DK DK ***
Cutting system, 1412024 Toothed belt, XL. 1451017 Clutch 6/6. 1455009 Cutting wheel. 1636186 Cutting slide. 1636187 Guideslide. 3010078 Micro switch 2.pol with arm. 3190007 H.P. encoder. 5802830 Tight/loop sensor kit. 5803288 Motor unit.
Rev/Type XL Steelcord 235.19.22 A A A SAIA XCK5-J4 HEDS 5500-C12 0 A
Cnt. JP *** GB *** DK *** DK *** DK *** CH SG US DK ***
Electronic module, 3600066 PSU 24Vdc. (sn < 68) 3600068 PSU 24Vdc. (sn > 68) 5601525S PCB Spindle motor driver. (sn < 68) 5803356S PCB Spindle motor driver. (sn > 68) 5601791S Spinner driver, Westwind. 5803503 SPDM module 5601526S PCB Scanner control module. 5601784 SCM 4 connectorboard. 5601785 SCM 5 connectorboard. 5601786 SCM 6 connectorboard. 5601787 SCM 7 connectorboard. 5601803 DC distribution board (sn > 68) 5601788 DC distribution board (sn < 68) 5803132S PGU 5R, MAGNUM. 5803235 PGU 5R connectorboard, (sn < 68) 5803135 PGU 5R connectorboard, (sn > 68)
Rev/Type A A C C D1373-18 A E, H C C C A A A B A B
Cnt. GB *** GB *** DK DK GB *** DK DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK ***
SERVICE MANUAL
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PAGE 9.1.3
Laser system, 3140028 Fan radial, dobbeltside UL. 3550028S Modulator 250 Mhz HRL. 3550042 Modulator 250 Mhz He-Ne. 3550030S Modulator driver 250 Mhz. (AR-He-Ne) 3600056S PSU 2114 for Ar-laser. 5601553 PCB PSU uniphase (f. PSU 2114) 3600069 PSU 10mw He-Ne laser 3600071 PSU 7mw He-Ne laser 5801982 Shutter for AR, He-Ne -Laser 3550029 Ar-laser 2214 HRL. 3550041 He-Ne-laser 10mw 3550045 He-Ne-laser 7mw 3550038 Optical fiber system for AR laser. 3550043 Optical fiber system for He-Ne laser. 5803161S IR-laser diode mod 2, 780nm. (2 res.) 5803404S IR-laser diode modul 3, 780nm (3 res.)
Rev/Type D4E 133-DA-05-94 LE 250 B M250-1E LANDWEHR LE252 2114 PSU A2 380T-3500 A 2214-10SL 1135P A A A A
Cnt. DE *** UK UK DE US 3 DK *** DK *** DK US US DK *** DK *** DK *** DK ***
Magazine, Rev/Type 5803145S Film magazine, MAGNUM. Magazine frame, 1341069 Gas spring 150N. 1341070 Laminated spring. 1412023 Toothed belt. 5803280 Motor for magazine, MAGNUM. 5801220 Lock handle f. magazien 5401936 Micro switch f. magazien with cable 3010104 Micro switch f. magazien Magazine module, 1309040 Roller foam seal ring. 1341039 Gas spring 60N. 1432130 Rubber roller. 1432131 PUR roller. 1461034 Foil cutter. Optic module, 5803178 Focus/Iris motor unit. (plate incl. focus-, iris motors and hall elements) 5801651 Hall element, type 1 (position) 5801666 Hall element, type 3 (rotation test) 5803311S Optical housing, Ar-laser. 5803312S Optical housing, Ir-laser, He-Ne laser PIM PC, 5601782S 8700400S 8700401 8700402S
Cnt. A Rev/Type 094854-150N A 280XL037 A
DK *** Cnt. DE *** DK *** JP *** DK *** DK
Rev/Type A 12-60-170-AA-60 B B B Rev/Type A
Cnt. DK DK DK *** DK *** DE Cnt. DK ***
1 1 Rev/Type A Rev/Type A1. D
DK *** DK *** Cnt. US DE *** DE *** DE *** Cnt. DK DK
PCB PC/BITBUS card, Micronetic. PIM PC unit & keyboard. PIM PC monitor. PIM PC unit w. bitbus card & keyboard.
Register module/filmguide, 1372019 Rubber space. 5801651 Hall element, type 1.
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PAGE 9.1.4
REV. E
5803276 5803321 5803335 5801654 5801673 5801750 5801751 5801752 5801753 5801754 5801755 5801756 5801772 5801785 5801786 5801787 5801788 5801789 5801790 5801791 5801792 5801875 5801905 5801906 5801922 5801923 5801973 5801974 5801976 5801977 5801988 5801989 5801996 5801997 5803109 5803110 5803111 5803112 5803113 5803114 5803128 5803129 5803133 5803134 5803137 5803138 5803139 5803151 5803152 5803186 5803188 5803207 5803233 5803234 5803244
Film guide right, MAGNUM. Film guide left, MAGNUM. Film flare guide (new version) Punch unit, 6.35 x 4.76. Punch unit, 8 x 4.76 Punch unit, 8/5-Y. Punch unit, 8/5-X. Punch unit, 5. Punch unit, 5.5. Punch unit, 6.35. Punch unit, 8/5.5-X. Punch unit, 8/6.35-X. Punch unit, 8/6.35-Y. Punch unit, 9.52/6.35-X. Punch unit, 9.52/6.35-Y. Punch unit, 7.94. Punch unit, 9.52/7.94-X. Punch unit, 9.52/7.94-Y. Punch unit, 3. Punch unit, 8/3-X. Punch unit, 9/5-X. Punch unit, 9.52/4.76-X Punch unit, 9.52/8-X. Punch unit, 9.52/8-Y. Punch unit, 6.35/4.72-X. Punch unit, 8/4.72-X. Punch unit, 9.52/4.76-X ICEA. Punch unit, 6.35 ICEA. Punch unit, 5 CHEMNITZ. Punch unit, 9/5-X CHEMNITZ. Punch unit, 5 WAZ. Punch unit, 8/5-X WAZ. Punch unit, 8/4.5-X Punch unit, 4.5 Punch unit, 8/5.5-X (90) HEINEN Punch unit, 8/5.5-X HEINEN Punch unit, 5.5 HEINEN Punch unit, 3.98 DIERICHS Punch unit, 8/3.98-X DIERICHS Punch unit, 8/3.98-Y DIERICHS Punch unit, 9.52/6.35-X HOLDEN Punch unit, 6.35 HOLDEN Punch unit, 4 CHRIST-CHURCH Punch unit, 5/3-X CHRIST-CHURCH Punch unit, 8/4-X TIROLER Punch unit, 8/4-Y TIROLER Punch unit, 4 TIROLER Punch unit, 6.35 Japs Olson Punch unit, 9.52/6.35-left Japs Olson Punch unit,9.52/6.35-right Japs Olson Punch unit, 8/4-X ZGT Punch unit, 8/4-X Lausitzer Punch unit, 5-horiz. VAF Punch unit, 8/5-horiz. VAF Punch unit, 5, short-side.
A A E E E E E E E E E E E E E E E E E E E E E E E B B B B B B B B A A A A A A A A A A B A B A A A A A A A A
DK *** DK *** DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK DK ***
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REV. E
PAGE 9.1.5
5803245 5803267 5803268 5803290 5803291 5803292 5803293 5803294 5803299 5803300 5803331 5803332
Punch unit, 8/5, short-side. A Punch unit, 9/5-Y. A Double Punch unit, Kieler Nachrecten A Punch unit, 9/5-X, staggered/long-slit. A Punch unit, 5, staggered. A Punch unit, 9/5-Y,staggered/long-slit.LA Punch unit, 5, staggered/long-slit. A Punch unit, 9/5-Y,staggered/long-slit.RA Punch unit, 9,52/6,36-X, long-slit. A Punch unit, 6,35, long-slit. A Punch unit, 9,52/6,35-X, special. A Punch unit, 9,52/6,35-X, spec. Stagg.R A Rev/Type 470B33/10/12 SS5GL2 SAIA XCK5-J4 VRDM597LNB A A A A
DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK *** DK *** Cnt. GB *** JP CH DE *** DK *** DK *** DK *** DK *** DK Cnt. US *** US***
Spindle module, 1451019 Clutch for spindle motor. 3010073 Slide micro switch. 3010078 Micro switch f. end stop. 3120039 Stepmotor, 5-fase. 5803180 Left endstop complete (Zeropoint) 5803181 IR hook switch. 5803184 Right endstop complete 5803283 Viscose damper, 12mm axel. 5801720 Carriage hall encoder (hall type 5)
Rev/Type Spinner system, 1431021S Spinner. Westwind. (AR, IR). DD1456-03 1431028S Spinner. Westwind. (He-Ne) 1431029S Spinner. Westwind. (Silver coated- AR,IR,He-Ne) Vacuum module, 3130011 Vacuum pump, SKG180-2.03 5801733 Vacuum sensor. 5803156 Bit bucket 5803269S 4-way vacuum valve. Rev/Type 101574-0358 A B1 B
Cnt. DE *** DK DK *** DK
Upgrade kits 4000125 FCO#1 (screen quality) Magnum/Mercur 4000112 Cylinder Vibration Dampner 4000117 Vacum Pump Vibration dampner 4000124 Flare Guides 4000123 SPDM driver module 4000114 DC/DC converter include cable 214 rev b. 4000116 10F capasitor in modulator driver cable 108.1 (rev d). 4000118 CCU vibration dampner 4000113 Automatic water feed 4000126 FCO#2 (pollution) Magnum/Mercur End of list.
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PAGE 9.1.6
REV. E
Cabinet Parts
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Front panel top Rear panel top Front panel bottom Rear panel bottom Side door top left Side dor top right Side door bottom left Side door bottom right Side panel left Side panel right Top panel 5803199 Rear panel - Magnum Rear panel - Mercury Chassis frame
5803190 5803192 5803189 5803191 5803196 5803194 5803195 5803193 5803198 5803197 5803200 5803413 5803226
SERVICE MANUAL
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REV. B
PURUP IMAGEMAKER MAGNUM MACHINE WIRING
PAGE 10.1.1
10.
Engineering Drawings, Machine Wiring and Diagrams
10.1. Machine Wiring
Number 5803135 WL 5601784 WL 5601785 WL 5601786 WL 5601787 WL
Rev. A A A A A
Type Wire List board Wire List board Wire List board Wire List board wire List board
for PGU5R Connector for SCM4 Connector for SCM5 Connector for SCM6 Connector for SCM7 Connector
Please refer to hardcopy of these pages
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PURUP IMAGEMAKER MAGNUM AD CHANNEL NUMBERS
PAGE 10.2.1
10.2. AD Channel Numbers See also chapter 2.1.2.2.2, Bitbus / A/D conversion. Filter value is always 15. SCM 4
Name US3 US10 HALL5 HALL12 HALL6 HALL13 HALL7 HALL8 HALL9 INDU1 INDU3 INDU4 ENC6 ENC7 ENC2/3 ENC4/5 SCM 5 Name HALL12 HALL6 HALL13 HALL4 HALL7 HALL2 HALL14 HALL8 US3 ENC1 INDU4 INDU5 INDU1 INDU3 HALL10 Descr. Hall reg. unit 5 Hall reg. unit 6 Hall reg. unit 7 Hall reg. unit 13 Temperature air (+) Temperature air (-) Temperature drum (+) Temperature drum (-) Out sensor "US7" Climate control, humidity Climate control, offline Climate control, fluid level Climate control, filter watch Climate control Filter watch Node Chan. Type 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 28 22 29 20 23 19 30 24 19 1 11 12 8 10 26 HALL HALL HALL HALL HALL HALL HALL HALL US HALL HALL HALL HALL HALL HALL Descr. Film sensor "US1" Belt sensor "US6" Hall reg. unit 1 Hall reg. unit 2 Hall reg. unit 3 Hall reg. unit 4 Hall reg. unit 12 IR sensor in drum "IR1" Film stop sensor on guide "IR3" Safety system on/off Film snip sensor Cut sensor Vacuum sensor (+) Vacuum sensor (-) Roller encoder Belt encoder Node Chan. Type 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 19 26 21 28 22 29 23 24 25 8 10 11 6 7 2/3 4/5 US US HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL
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PAGE 10.2.2
REV. C
ENC4/5 ENC6 ENC7
Cutter encoder Cut switch left Cut switch right
5 5 5
4/5 6 7
HALL HALL HALL
SCM 6 Name ENC4 HALL5 HALL11 ENC1 HALL6 HALL4 HALL1 HALL2 HALL3 HALL8 HALL9 ENC2 ENC3 INDU1 INDU2 INDU3 INDU4 Descr. Magazine proximity switch Hall (inner) magazine Hall (outer) magazine Magazine encoder Hall A vacuum valve Hall B vacuum valve Hall focus ref. Hall focus end. Hall focus rot. Hall iris ref. Hall iris rot. Filmprocessor PROCON Filmprocessor PRORDY Filmprocessor PROFIN Filmprocessor PROTEMP Filmprocessor PROLEVEL Filmprocessor PROJAM Node Chan. Type 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 4 21 27 1 22 20 17 18 19 24 25 2 3 8 9 10 11 HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL HALL
SCM 7 Name HALL5 HALL12 HALL6 HALL13 HALL7 Descr. Hall reg. unit 8 Hall reg. unit 9 Hall reg. unit 10 Hall reg. unit 11 Hall reg. unit 14 Node Chan. Type 7 7 7 7 7 21 28 22 29 23 HALL HALL HALL HALL HALL
PGM5 Name Type Right endstop Left endstop Zero pin sensor Descr. Node Chan.
Hall input 1 Hall input 2 Hall input 3
1 1 1
1 2 3
Hall Hall Normal
SERVICE MANUAL
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REV. C
PAGE 10.2.3
Current measurement Safety loop Safety loop Left emerg.stop Right emerg.stop Mid. emergency Laser Current monitor Laser Diode temp. Input Laser Power ARION
Laser Power monitor Laser Power Laser Power Emergency input (EINP1) Emergency input (EINP3) Emergency input (EINP3) Emergency input Emergency input Emergency nput
1 1 2 1 1 1 1 1 1
22 4 5 6 8 7 20 21 27
Normal Normal Normal Normal Normal Normal Normal Normal Normal
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REV. G
PURUP IMAGEMAKER MAGNUM ELEC. ENG. DRAWINGS
PAGE 10.3.1
10.3. Electronics Engineering Drawings
Please refer to hardcopy of these pages
Number 8990000 WI 5601784-DI 5601784-DI 5601784-ST 5601785-DI 5601785-DI 5601785-ST 5601786-DI 5601786-DI 5601786-ST 5601787-DI 5601787-DI JDP5925-0 5601783 DI 5601783 DI 5601783 5601782 ST 5601522 ST 5601522 DI 5601553 ST 5601553 DI 5401536 ST 5601525 ST 5601525 WT 5803183 5803317 5601788 DI 5601802 DI
Pg. 1 1/2 2/2 1/1 1/2 2/2 1/1 1/2 2/2 1/1 1/2 2/2 1/1 1/3 2/3 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1
Rev. A C C C C C C C C C 1 1
Type Wiring List SCM4 Connector Board SCM4 Connector Board SCM4 Connector Board SCM5 Connector Board SCM5 Connector Board SCM5 Connector Board SCM6 Connector Board SCM6 Connector Board SCM6 Connector Board SCM7 Connector Board SCM7 Connector Board SCM7 Connector Board C PGM5R Connector Board C PGM5R Connector Board 970523 PGM5R Connector Board Film Processor Interface B PC Bitbus Card, Jumper Config. D PCB On/off Switch D PCB On/off Switch A PCB Uniphase PSU A PCB Uniphase PSU B External Bitbus C1 Spindle driver assembly C1 Spindle motor/driver system A AC Power Box B AC Power Box B DC Distribution Board A Power Distribution Board
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PURUP IMAGEMAKER MAGNUM MEC. & OPTICS ENG. DRAWINGS
PAGE 10.4.1
10.4. Mechanics & Optics Engineering Drawings
Mechanics: Number S5801654 5801976 ST 5801983 ST 5803145-ST 5803146 EXP 5803147 EXP 5803149-EXP 5803155 ST 5803237 ST 5803398 ST ELETEK101 Z00-T005 Pg. Rev. Type 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 F C A D D C B D B B A 1 Register Unit Assembly Register Unit Argon Laser Unit, W/shutter Magazine Conveyor Cutting System Loader System Vacuum System Assembly of Film Output Slit Assembly of Film Output Slit, B2 Magnum/Magnum RS-Outline AOM/Fibre Adjustment
Click on drawing to display
PURUP PREPRESS A/S
SERVICE MANUAL

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REV.

PURUP IMAGEMAKER MAGNUM

PURUP IMAGEMAKER MAGNUM

Rev. G June 1998

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM REVISION STATUS

ToC6, chp. 6.2, chp. 6.3 Front Page, Revision Page

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL INFORMATION

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM SAFETY

Earth the instrument

Do not operate in an explosive environment

Keep away from live circuits

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM SAFETY

Do not service or adjust alone

Use caution when exposing or handling the CRT

Do not substitute parts or modify equipment

Dangerous Procedure warnings

Radiation of Radio Frequency Energy

PURUP IMAGEMAKER MAGNUM SAFETY

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM SAFETY

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM SAFETY

LASER RADIATION AVOID EXPOSURE TO BEAM CLASS 3B LASER PRODUCT

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION

1.3. General Description

1.3.1. Functional Specifications Electrical Data

1.3.1.1.1. Recording Format

Max. (vertical x horizontal): Horizontal: Vertical:

820 x 1200 mm or 32.3 x 47.2 inch around drum along drum

1.3.1.1.2. Photographic Material Format

Max. (vertial x horizontal): Min. (vertical x horizontal):

820 x 1200 mm 400 x 250mm

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION

1.3.1.2.1. Absolute Linearity

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION

Total "worst case"

20 in.: Max. format y-direction 26 in.: Max. format x-direction

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION

Total "worst case"

20 in.: Max. format y-direction 26 in.: Max. format x-direction

PURUP PREPRESS A/S

PURUP IMAGEMAKER MAGNUM GENERAL DESCRIPTION

1.3.1.3.2. Recording Spot Size on Film

26 m at 20 m in addressability 13 m at 10 m in addressability 10.4 m at 8 m in addressability 8.4 m at 6.4 m in addressability 8.4 m at 5 m in addressability

1.3.1.3.3. Recording Speed (10 and 20 m) 1.3.1.4. Screen Variations

16 mm/sec (20 m) 8 mm/sec (10 m)

+/- 1% relatively measured.

1.3.1.5. Density Variations

Maximum standard variation of selected density:

1.3.1.6. Register System

1.3.1.6.1. Register System Limitations

Maximum number of punch units (standard):

PURUP PREPRESS A/S