Barco SilverWriter 800 Quick start guide

Field Service Manual December 2003
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SilverWriter 800 Multi Format Family
Laser plotters
Field Service Manual
December 2003

Field Service Manual December 2003
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Copyright
© Copyright 2002 ManiaBarco N.V., Gent, Belgium
All rights reserved. This material, information and instructions for use contained herein are
the property of ManiaBarco N.V. The material, information and instructions are provided on
an AS IS basis without warranty of any kind. There are no warranties granted or extended by
this document. Furthermore ManiaBarco N.V. does not warrant, guarantee or make any
representations regarding the use, or the results of the use of the software or the information
contained herein. ManiaBarco N.V. shall not be liable for any direct, indirect, consequential
or incidental damages arising out of the use or inability to use the software or the information
contained herein. The information contained herein is subject to change without prior notice.
Revisions may be issued from time to time to advise of such changes and/or additions.
No part of this document may be reproduced, stored in a data base or retrieval system, or
published, in any form or in any way, electronically, mechanically, by print, photoprint,
microfilm or any other means without prior written permission from ManiaBarco N.V.
This document supersedes all previous dated versions.
Trademarks
All product names cited are trademarks or registered trademarks of their respective owners.
Correspondence regarding this publication should be forwarded to:
ManiaBarco
Tramstraat 69
B-9052 Gent

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Table of Contents
TABLE OF CONTENTS........................................................................................................ 3
GENERAL INFORMATION - BLOCK DIAGRAM ................................................. 7
GENERAL INFO SW8XX ..................................................................................................... 9
Machine mode....................................................................................................................... 9
Film sizes .............................................................................................................................. 9
Drumspeeds for SW8xx........................................................................................................ 9
Number of beams.................................................................................................................. 9
Operator switches................................................................................................................ 10
SilverWriter connections..................................................................................................... 13
Online switch ...................................................................................................................... 14
SILVERWRITER MF SITE PREPARATION CHECKLIST .............................. 15
BLOCK DIAGRAM SILVER WRITER ..................................................................... 19
DESCRIPTION OF THE BOARDS + ADJUSTMENTS ..................................... 21
THE LASER TOOL LANGUAGE : LTL ..................................................................... 25
Commands .......................................................................................................................... 28
General................................................................................................................................ 28
Carriage............................................................................................................................... 29
Feeder and drum.................................................................................................................. 30
Optic.................................................................................................................................... 31
Parameters........................................................................................................................... 33
Pump ................................................................................................................................... 35
LASER TOOL LANGUAGE UPDATES.......................................................................... 36
FILM FEEDER ................................................................................................................... 37
Adjusting the Film Feeder................................................................................................... 37
The Film Feeder Parameter Settings................................................................................... 54
Load process........................................................................................................................ 59
Unload process.................................................................................................................... 68
Vacuumpump...................................................................................................................... 74
The Vacuum Pump Box Components/Layout. ................................................................... 75
MF Electrical Solid State panel........................................................................................... 80
MF Relief valve system ...................................................................................................... 81
SilverWriter MF Valve System........................................................................................... 82
MF SilverWriter SUPPORT ROLLER............................................................................... 83
SilverWriter MF Pump CONTR box.................................................................................. 84
Filmsize adjustment on MFF .............................................................................................. 85
ELECTRICAL DEVICES ................................................................................................. 91
Power panel......................................................................................................................... 91
Circuit breakers................................................................................................................... 92
Solid state Panels................................................................................................................. 93
Drum Micro Master Parameter Table MM750.................................................................. 97

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Drum Micro Master Parameter Table MM440 0.75KW................................................. 100
DESCRIPTION OF THE PNEUMATICS ............................................................... 109
Shutoff Valve.................................................................................................................... 110
Manometer & Pressure Regulator..................................................................................... 110
Air Filters.......................................................................................................................... 110
Carriage Air Bearings ....................................................................................................... 112
Air Bags ............................................................................................................................ 114
Blowpipe........................................................................................................................... 116
Air speed controls ............................................................................................................. 116
Suction Caps & Vacuum Ejector ...................................................................................... 118
FRONT DOOR ADJUSTMENT .................................................................................. 119
INSTALLATION OF LINEAIR SCALE .................................................................. 123
INSTALLATION OF RSF ENCODER ..................................................................... 127
DOWNLOADING LTL SOFTWARE IN TO MACCON ...................................... 131
COPYING PARAMETERS BETWEEN TWO MACCON’S ............................... 133
HOW TO DOWNLOAD SSIPRO SOFTWARE (ON A 32 MBYTE ........... 135
PARAMETER LIST ........................................................................................................ 137
Parameters : : explanation............................................................................................... 137
Editing-Exit parameterlist................................................................................................ 151
Adjusting parameter values............................................................................................... 151
SW860 - MF...................................................................................................................... 152
SW830 - SF....................................................................................................................... 160
INSTALLATION OF CARRIAGE ON GRANITE ............................................... 169
Assembling and Mounting of the Base Carriage and linear motor................................... 169
INSTALLATION OF OPTIC ON CARRIAGE ..................................................... 173
OPTICS 600......................................................................................................................... 175
Introduction....................................................................................................................... 177
Electronic boards in the machine rack.............................................................................. 180
Theory of the optics .......................................................................................................... 181
Adjustment procedure Optics 600..................................................................................... 184
Alignment of the laser path............................................................................................... 188
Brief explanation of the laser path adjustment.................................................................. 204
TESTJOBS – FREQ AND DELAY ............................................................................ 207
POWERRIP ...................................................................................................................... 211
License file........................................................................................................................ 211
How to update-Install to PowerRip version 2.04 or higher............................................... 212
Resource files.................................................................................................................... 228
TESTJOBS - DENSITY AND LINEWIDTH ........................................................ 235
EXPOSE COMMANDS .................................................................................................. 241

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MANUALLY SUBMITTING JOBS IN THE POWERRIP PLOT QUEUE .. 243
TESTJOBS - FILM3&4 GEOMETRIC ACCURACY CHECK .......................... 247
UCAM - SMARTPLOT INSTALL CONFIGURATION ...................................... 249
Smartplot Console on PowerRip....................................................................................... 251
ERROR LIST SILVERWRITER 800 .............................................................. 253
Carriage............................................................................................................................. 253
Optic.................................................................................................................................. 255
General.............................................................................................................................. 257
Feeder - Drum................................................................................................................... 258
Communication................................................................................................................. 264
Film-Job Quality ............................................................................................................... 265
PLOT TIME CALCULATION ..................................................................................... 269
FILM PROCESSOR CONNECTION ........................................................................ 271
INSTALLATION PHASE ............................................................................................. 273
TOOLS FOR CUSTOMER CARE ENGINEERS ................................................... 273
SUPPORT .......................................................................................................................... 275
Contact information ................................................................................................... 275
Helpdesk ManiaBarco - Asia ................................................................................... 276
Helpdesk ManiaBarco - Europe, Middle East and Africa .............................. 276
Helpdesk ManiaBarco - North America and Latin America ......................... 276

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Compressed air tube
2 x 230V input
Indication lamp
Vacuum tube &
control signals Ethernet
General information - Block Diagram
Imager Room
Green Safe light 230 V
PowerRip
Data cable Ethernet
+
Vacuum Pump area
3 Phase Power Input
Composing area
Ucam
230 V
Compressor area
230 V
2 x RS-232
2 x RS-232
2
30 V

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General info SW8xx
Machine mode
1. Expose mode (customer operating mode)
After booting : Expose ? E
2. Test mode (LTL)
After booting : Expose ? L
Film sizes
Drumspeeds for SW8xx.
Untill 20320ppi
-drumspeed 26rev/sec
-24 beams
20320ppi
-drumspeed 25rev/sec
-24 beams
25400ppi
-drumspeed 20rev/sec
-24 beams
Number of beams
SW860 : 24 beams exposure (optic 24 beams)
SW830 : 12 beams exposure (optic 24 beams)
SW815 : 6 beams exposure (optic 24 beams)

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Operator switches
Door Button.
The door button is used to open or to close the front door (i.e. a rolling-shutter). This
is needed to access the film cassette and drum area.
Ones the door button is pressed first the filmfeeder bridge will move up and second
the door will open. The bridge is first moved up so the cassette is free for film
installation.
The door can also be opened by pressing ‘d’ and confirming with ‘y’ at
Ready to work. In this case the door will open but the feeder bridge will stay down.
On Button.
The On button switchs on the vacuum pump.
This is only needed to load a film manually.
In standby mode the button appears green.
Off Button.
The Off button switchs the vacuum pump off e.g. after exposing with manual
load. In standby mode the button appears green.

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Status Lamp.
This lamp has two functions:
· Continues light: drum is spinning.
· Flashing light : No film in machine.
A severe error has occurred.
This same function can also be seen on the external (optional) indication
lamp.
In standby mode the button appears dimmed.
Machine Stop Button.
The stop button stops the machine at any time. It is located on the console, at
the right hand side of the machine.
Index LED.
This LED shows the index position of the drum.
The color of the LED is green.
Main On/Off Switch.
This switch is used to switch the main power of the SilverWriter on or off. The

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main 220V input and the UPS 220V input are simultaneously switched on/off.
The switch is located on the connector plate on the left backside of the SilverWriter.

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SilverWriter connections
All connections ‘power-indication lamp-pump connections-SW communication
cables-air pressure’ are located at the right rear side of the machine.

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Online switch
B
A
Switch I: Unloading into drawer
II : Unloading to developer – except when developer doesn’t accept
films(film stays on top of onlinedetector). Than films are going
into unloaddrawer. SilverWriter will keep exposing if parameter
‘Unload in drawer’(B-option of parameterlist) is on ‘Y’. If this
parameter is on ‘N’ SilverWriter will stop exposing.
LED : A : ON -> Online up – film to unload drawer or film chortly on online
detector for developing.
OFF -> Online sensor free. Film can go to developer
LED : B : OFF -> Transportermotors not working
Blinking -> Transportermotors working

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SilverWriter MF Site Preparation Checklist
Customer code:
Plotter type:
Customer contact 1:…………………….. Function: ……………………………...
Customer contact 2:…………………….. Function: ………………………………
Customer contact 3: …………………….. Function: ………………………………...
Customer contact 4: …………………….. Function: ………………………………
Installation address:
……………………………………………………………………………………..
……………………………………………………………………………………..
…………………………………………………………………………………..
………………………………………………………………………………………..
Plotter size: width=1725mm, depth=2358mm, min depth=1500mm, height=1825mm, service
height=2480mm, weight=1500 kg
Crate size: width=2010mm, depth=2766mm, height=2079mm, 500 kg (2000 kg with plotter)
Has the customer received the pre-installation manual? Yes No
Does the customer have a storing place for the crate? Yes No If
no, plastic must be available to cover the crate
Forklift truck to unload plotter from truck (2000kg load, long blades) must be
available
Manual forklift (1500kg) must be available during installation
The entrance for the plotter and corresponding passageways or corridors
must be free from obstacles
Is the floor (including passageways) stable enough? Yes No
(install thick metal plates)
Does the floor of the plotter room need to be reinforced? Yes No
Will a film processor be online connected to the plotter? Yes No
The plotter room must be big enough (+1.5m space at drawer side, +1m
space at front and right side, 2.5m height)
Vibrations must comply with specs, in case of doubt contact specialized
company
Vacuum pump box must be installed in a dry and clean area (max temp 30°C)
outside the plotter room. 75dB , 2.7kW at 250mbar , 50
°C
Vacuum tube length to plotter →maximum 15m, outer ∅= 72mm
minimum (supplied by Barco)
Vacuum pump box command cable connector ∅= 35mm (supplied by
Barco)

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Power cable 230VAC 3phase 25A 6 mm² (protected with 32A very
slow fuse) to the vacuum pump
or Power cable 380VAC 3phase 12A 4 mm² (protected with 25A very
slow fuse) to the vacuum pump
Install transfo if the required Voltages are not available(ex.:from 207V -> 230V)
Customer should provide an UPS for the plotter,will one be available? Yes No
Two 230VAC outlets (1 x UPS 1kW and 1 x 6A) must be available at back left of
plotter
Two 230VAC outlets (1xUPS 500W)must be available for the plotter PowerRip PC
Ground (earth) of power outlets must be interconnected!
At least two 230VAC outlets (UPS 100W) must be available for maintenance
(oscilloscope, lamp,…)
Status lamp (red) mounted against wall of yellow room (230 VAC, light bulb 100
W max) (optional)
Plotter room must be equipped with correct fittings for green safety lamps
(lamp tubes supplied by
Barco)
Tube cyan T20-60cm (x4)
Tube cyan T20-120cm (x2)
Tube cyan T20-150cm (x2)
Plotter room must be equipped with sufficient number of white light fittings
Adequate air conditioning must be available and in working order (temperature,
relative humidity, airflow)
Customer has to provide a transceiver box to connect the plotter to his network
(UTP twisted pair
 ...)
Working telephone connection must be available in the plotter room for service
purposes
Tables for the plotter PowerRip PC and film box storage must be available
Compressed air connection must be available. 6-10 bar , 2500 l/h
Compressed air filter (water/oil, dust) must be installed on the wall in the plotter
room (0.01mg/m³, 3µm max)
The film processor must be flat on the front towards the conveyor side
Height and distance to first take up roller
Correct chemicals must be available at start of installation
Film processor (installed through the wall) must be ready to work at
start of installation
Films of the right type and size must be available at start of installation
A workstation complying to the Ucam specs with the Ucam/Smartplot software
installed must be available
Does the customer have a densitometer D>5 (is must for AGFA RL7&STD,
KODAK)? Yes No
Does the customer have a measuring table / tool? Yes No
Light table of correct film size must be available
Does the customer want installation material before the installation? Yes No

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1 x vacuum hose 15 m length, outer ∅= 72mm minimum
1 x power cable vacuum pump box, cable ∅=16mm, connector ∅=35mm (male
connector at plotter side)
1 x quick acting coupler female part, ¼ F
1 x conveyor connection plate to film processor
Type of film processor Brand: Flat front? Yes No(supplier must adapt it)
Model: Production year:
Type of film Brand: Type:
Size:
(plot size = film size - max 0.1” at left/right/bottom and 0.8” at top)
Plotter room must be completely finished before the installation starts
(requirements see above); plotter is to be unpacked by the ‘Barco’ engineer,
otherwise warranty is void.
Crate is to be returned.
If at installation time (engineer is on site) it appears the site is not completely
ready, contradictory to what the customer told/promised, all extra costs (lost time,
return to finish installation) will be charged to the customer.
Remote diagnostics
on Plotter 8xx Series
All Barco plotters in the 8xx series (i.e. SILVERWRITER 8XX, BG 748xx, BG
758xx and BG 768xx) are delivered with a modem. When ordering, be sure
the customer’s choice is indicated: either the
analog modem (code 966208)
or ISDN modem (code966209).
REMARKS:
Enough space around machine ? Also to open drawer ? ……………………………
Be sure that the film can go through the developer !
…………………………………………………………………………………
…………………………………………………………………………………
…………………………………………………………………………………
…………………………………………………………………………………
……………………………………………………
Date: Date:
Name customer (capitals): Name field engineer:
Signature: Signature:

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Block Diagram Silver Writer
Remark: Refering also to drawing documents

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