Glunz & Jensen PlateWriter 2000 User manual

Service Manual
PlateWriter™2000

Service Manual
PlateWriter™ 2000
Edition AB, November 2016
This book has part No 10078573
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This manual is published by: GLUNZ & JENSEN A/S
Selandia Park 1
DK-4100 Ringsted
Denmark
Phone:[phone]
E-mail: [email protected]
Internet: www.glunz-jensen.com
© 2015 Glunz & Jensen A/S. All rights reserved.
Service Manual - PlateWriter™ 2000 1545
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1545 Service Manual - PlateWriter™ 2000
Table Of Contents 0-3
Table of Contents
Part 1: Introduction ...............................................1-1
About this manual ................................................1-1
Intended use of this manual .......................................1-1
Reservations ..................................................1-1
Important ......................................................1-1
Unintended use of the equipment....................................1-1
Installation ...................................................1-1
Notes, cautions, and warnings ! .....................................1-2
Chemicals ....................................................1-2
''End of lifetime'' disposal..........................................1-2
Service assistance ..............................................1-2
The Functional description of the PlateWriter system ........................1-3
The System consists of: ..........................................1-3
Part 2: The Printer ................................................2-1
Initial startup of PlateWriter 2000 .....................................2-1
Turning on the printer & setup ......................................2-2
Installing ink cartridges ...........................................2-3
Printer setup ....................................................2-4
Auto nozzle check ..............................................2-4
Auto cleaning..................................................2-4
Installing the Epson 4880 printer ......................................2-5
Renaming the Epson printer to PW2000...............................2-5
Launching the RIP for the first time ..................................2-7
Bi-directional adjustment on PlateWriter 2000 ............................2-8
Adjusting the printer feed ...........................................2-9
Background ...................................................2-9
Tools .......................................................2-9
Adjusting the side registration system ..................................2-11
Procedure ...................................................2-11
Part 3: The Finisher ...............................................3-1
General ........................................................3-1
Connection the FU to the RIP PC ....................................3-1
Windows XP: ...............................................3-1
Windows 7: ................................................3-1
Parameters setting ................................................3-2
Default parameters setting for PlateWriter 2000 .........................3-2
Recommended parameters setting for PlateWriter 2000..................3-4
Commands .....................................................3-5
Diagnostic Input................................................3-5
Input sensors: ...............................................3-6
Diagnostic Output ..............................................3-8

Service Manual - PlateWriter™ 2000 1545
Table Of Contents
0-4
Diagnostic Current ..............................................3-8
Adjustments.....................................................3-9
Plate temperature settings (BE) .....................................3-9
Adjusting temperature settings....................................3-9
Gum/water replenishment settings (GR) ...............................3-9
Part 4: RIP Installation ............................................4-1
Overview .......................................................4-1
Connecting the System and optional proofer to your RIP workstation .............4-1
Epson 4880 & 7880 proofers only ...................................4-1
Installing the Navigator RIP for Windows.................................4-2
General ......................................................4-2
Before installing the Navigator RIP ..................................4-2
Overview .....................................................4-2
Installing the Navigator RIP, plug-ins and manuals........................4-3
Renaming the Epson printer to PW2000..............................4-18
Launching the RIP for the first time .................................4-20
Configuring the RIP ............................................4-25
Activating the color proofing option .................................4-28
Epson proofing activation ......................................4-28
Part 5: Trouble shooting ...........................................5-1
General ........................................................5-1
Before starting troubleshooting ........................................5-1
Problems with the finishing unit .......................................5-2
Indicator status and error codes .....................................5-2
Part 6: Spare parts ................................................6-1
Finding a spare part .............................................6-1
Ordering a spare part ............................................6-1
Original printer spare parts ........................................6-1
Appendix A: Electrical diagrams ....................................A-1
Main power distribution.............................................A-2
Main switch and primary voltage ....................................A-2
Low voltage wiring ................................................A-4
Sensors, switches, LEDs and motors .................................A-4
Printer plane ....................................................A-6
Wiring schematic ...............................................A-6
Optional ink dryer .................................................A-8
Wiring schematic ...............................................A-8

Part 1: Introduction
About this manual
Intended use of this manual
•This manual describes how to install software and firmware to the PlateWriter 2000
system. The procedures described in this manual require a reasonable level of tech-
nical skill and access to the proper tools.
Reservations
•This manual was written and illustrated using the best possible information avail-
able at the time of publication.
•Any differences between this manual and the equipment reflect improvements intro-
duced after the publication of the manual.
•Changes, technical inaccuracies and typographical errors will be corrected in subse-
quent editions.
•As a part of our policy of continuous improvement, we reserve the right to alter de-
sign and specifications without further notice.
Important
Unintended use of the equipment
Glunz & Jensen A/S do not take any responsibility for any damage or accidents caused
by unintended use of the equipment:
•As the equipment is certified by accredited test laboratory (UL International Demko
A/S) it is absolutely prohibited to make any modifications, electrical nor mechanical,
of the equipment. If however this prohibition is disregarded, Glunz & Jensen's war-
ranty will no longer apply and the certification labels for UL, C-UL, and
CE certification of the equipment shall be removed as the certification will no longer
apply to the equipment.
Installation
•Never install the equipment in explosive environments.
•It is the responsibility of the owner and operator/s of the equipment, that the instal-
lation is made in accordance with local regulations, and by engineers authorized to
carry out electrical installations.
•Installation must be performed only by service technicians who are trained in install-
ing the equipment.
•The manufacturer cannot be held responsible for any damage caused by incorrect in-
stallation of this equipment.
1545 Service Manual - PlateWriter™ 2000
1-1
Introduction
About this manual

Notes, cautions, and warnings !
Throughout the manual notes, cautions, and warnings are written in bold like the
example below:
$Always replace a fuse with one of the same size and rating as the old one.
Symbol Meaning Explanation
"Note
The operator should observe and/or act according to the
information in the order to obtain the best possible
function of the equipment
$Caution
The operator should observe and/or act according to the
information in the order to avoid any mechanical or
electrical damage to the equipment.
#Warning
The operator should observe and/or act according to the
information in the order to any personal injury.
Chemicals
•It is responsibility of the owner of this equipment that data is available to concerning
possible health risk from the chemicals used with the equipment.
''End of lifetime'' disposal
•The equipment is designed for easy disassembling. All disposal of parts from the
machine must be made according to local regulations. For recycling purposes signifi-
cant components are marked with material specification according to the ISO 11469
standard.
Service assistance
•If help is needed to correct any problem with the equipment, please contact your
local supplier.
Service Manual - PlateWriter™ 2000 1545
1-2 Introduction
Important

The Functional description of the PlateWriter system
The system is an innovative and patented inkjet Computer-to-Plate (iCtP) device.
The System consists of:
•Plate Writer engine (1)
A specially modified Epson inkjet printer that uses 's fluid to image the i-plates
printing plates.
•Plate input table (2)
A table for aligning plates prior to entering into the engine.
•Proofer (option)
An unmodified Epson Stylus Color 4800, 4880 or 7800, 7880 printer used for proof-
ing. Plug-ins to drive these printers are supplied with the Harlequin RIP.
•Harlequin RIP platform
A customized workstation accessible by both Mac and PC computers, loaded with
the Global Graphics Harlequin RIP.
The Harlequin RIP provided is customized by Xitron and it accepts PostScript, PDF,
EPS, TIF & JPEG files produced by standard pre-press applications.
It RIPs the data and sends output to the engine or to the Proofer.
•Plate Writer finishing unit (3)
An integrated plate finisher that executes all of the steps necessary to produce
press-ready plates, e. g.: curing, gumming and drying of the plates after they are
imged in the engine.
1545 Service Manual - PlateWriter™ 2000
1-3
Introduction
The Functional description of the PlateWriter system
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Service Manual - PlateWriter™ 2000 1545
1-4 Introduction
The Functional description of the PlateWriter system

Part 2: The Printer
Initial startup of PlateWriter 2000
•Remove all the packing materials and tape. Check carefully for all the tape inside
and outside the printer.
•Remove the two screws and the carriage retainer bracket.
•Unlock the print head carriage by pulling the green tab on the left. Do not remove
the tab.
"Do not press down the green tab or it may break.
1545 Service Manual - PlateWriter™ 2000
The Printer 2-1
Initial startup of PlateWriter 2000
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Turning on the printer & setup
•Connect the power cord to the AC inlet on the back of the printer. Do not connect
the printer cable yet.
•Plug the other end of the power cord into a properly grounded electrical outlet.
The Printer
2-2 Initial startup of PlateWriter 2000
Hardware Installation - PlateWriter™ 2000 1545
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Installing ink cartridges
•Press the power button to turn on the
printer.
•Press both ink compartment covers to
open them.
•Raise both ink levers.
•Remove each fluid cartridge from its
package and gently shake.
"The first time you install fluid
cartridges, the printer uses some
fluid to charge the printing system,
so print yields may be lower with
the first cartridges. Subsequent
fluid cartridges will last their full
rated life.
•Install the cleaning fluid cartridges in the
printer. Hold each cartridge with the ar-
row pointing towards the printer, then
insert it into its slot. Make sure that you
insert each cartridge in the correct slot.
•After installing all 8 cartridges, lower the
ink levers. The printer begins charging
the fluid delivery system and the
pause light flashes. When the display
shows 20%, raise the levers and replace
the cleaning cassette with Liquid Dot in
channels1&2.Lower the lever again.
$Charging takes about 8 minutes.
Never turn off the printer, open the
cover, remove the rear cover, release
the paper lever, or remove the ink
cartridges or maintenance tank
while the pause light is flashing,
or you may damage the printer.
•When READY appears on the LCD dis-
play, charging is complete. Close the ink
compartment covers.
$Always turn off the printer using
the power button. Then wait
until the LCD display turns off.
This ensures that the print head is
safely capped.
1545 Service Manual - PlateWriter™ 2000
2-3
The Printer
Initial startup of PlateWriter 2000
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Printer setup
"IMPORTANT! The function with auto nozzle check and auto cleaning is not
used with the PlateWriter system, since there are no visible fluids in 6 of the 8
channels, and the printer will assume that the nozzles are missing. The printer
will continue to perform cleaning and try to recover the missing nozzles in the
6 channels with maintenance fluid.
To avoid annoying interruptions in processing, you should set auto nozzle
check and auto cleaning functions to "off".
Auto nozzle check
When you select ON, the printer performs a nozzle check before printing, for each
print job.
The printer must be set to OFF.
Auto cleaning
When you select ON and perform a nozzle check from the printer driver or the control
panel, the printer not only checks for clogged nozzles, but also performs head cleaning
automatically.
The printer must be set to OFF.
Service Manual - PlateWriter™ 2000 1545
2-4 The Printer
Printer setup
PRINTER SETUP
AUTO NZL CK
AUTO
OFF
ON
PRINTER SETUP
AUTO CLEANING
AUTO
OFF
ON
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Installing the Epson 4880 printer
$The procedure described below presumes that the RIP Workstation has been
properly installed and it is started up and ready.
•Connect the USB cable from the RIP Workstation to the USB plug on the rear side of
the PlateWriter (see picture below) and make sure that the unit is switched on.
Renaming the Epson printer to PW2000
For the RIP to see the PlateWriter, it is needed to rename the previously installed
Epson Stylus Pro 4880 printer driver to PW2000:
•Select the Windows Start button in the bottom left corner of the screen, then select
Devices and Printers.
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2-5
The Printer
Installing the Epson 4880 printer
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•The Devices and Printers window will appear.
Right click on the Epson Stylus Pro 4880 printer, and from the appearing menu
select Printer properties.
•The Epson Stylus 4880 Properties window will appear.
•The printer name becomes selected, now rename the Epson Stylus Pro printer to
PW2000 and press Ok.
•The printer name is changed.
Service Manual - PlateWriter™ 2000 1545
2-6 The Printer
Installing the Epson 4880 printer
PW2000

Launching the RIP for the first time
First plug in the dongle.
"If you do not plug in the dongle, the RIP will fail to launch with a "Super Pro,
C Plus Activator dongle not plugged in or invalid" error.
•Locate the Navigator icon which was placed on your desktop by the installer.
•Double-click it to launch the RIP.
•When launching the RIP for the very first time, it will ask to select User Interface
Language.
•Select English (United States). This is the keyboard map for the keyboard supplied
with RIP workstation.
•When selected the User Interface Language, the RIP will advise that it will need to
restart.
"If the German user interface is installed, it can be enabled here. Choose
German, click Enable, type the password and click OK.
•The RIP will advise that it will boot into chosen language next time.
•Click OK to continue and then restart the RIP.
•Next step is start to using the RIP (see Part 4).
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2-7
The Printer
Installing the Epson 4880 printer

Bi-directional adjustment on PlateWriter 2000
•Start the Program “PWAdjUtil” from the folder C:\GJ tools\PWAjUtil on the RIP
workstation.
•Select the printer connected.
•Select printer type and set Adjustment
job to Bidirectional and click on Narrow
(*).
•Load a 0,15 mm or 0,2 mm (*) plate in the
iCtP printer and click Print. The follow-
ing image (shown in black) will appear
on the plate:
The Figure PK/MK, 5 in the above show case, indicates the actual setting and
represents the line in the center. If the best line is not in the center position you must
find the best and enter the best value in the VSD 3 of the utility and click “Write”. The
correct figure is found by counting the lines from the center line and to the best line.
Notice that the distance between the lines is in steps of 2. You might find that two lines
that are equally good and you then set the value between the two lines e.g. if lines +2
and +4 are good you set the new value to5+3=8.
After setting the new value it is recommended to run the adjustment again to ensure
that the setting is correct.
(*) If the 0,2 mm reaches the head surface you must readjust the head height so that the
adjustment can be done on Narrow head height.
The Printer
2-8 Bi-directional adjustment on PlateWriter 2000
Service Manual - PlateWriter™ 2000 1545

Adjusting the printer feed
Background
In continuance to increase the print quality we often get questions on graininess. The
number one adjustment that reduces grainy looking tints is the printer feed
adjustment. The printer already has a feed adjustment built in but since the correction
depends on the plate thickness the correction value must be set in the page setup. This
makes it possible to ensure perfect feed for all plate gauges used.
Tools
•Start the Program “PWAdjUtil” from the folder C:\GJ tools\PWAjUtil on the RIP
workstation.
•An accurate ruler for measuring the feed.
•Start the PW Adjustment Utility, select the printer and type in question and print the
file as shown below:
Notice that you must select a suitable file (inch or metric) depending on the ruler you
have.
Load a plate in portrait on the PlateWriter, press Print in the utility. After the job has
been printed place a ruler on the best line of fit.
The Printer 2-9
Adjusting the printer feed
1545 Service Manual - PlateWriter™ 2000

Measure the longest possible line 250, 450 or 600 mm and find the deviation factor as
shown.
In this case the feeds needs to be adjusted +0,16% measured at the 25 cm point.
Open the page set-up(s) with plate gauge identical to the one performed for the above
test and key in the new value in the Feed adjustment in the “Configure Device.”
The feed on different plate thicknesses might be different so if other plate thicknesses
are used you must run the same test again using the corresponding plate. If the value
turns out to be different you can key in the value in the relevant page set-ups.
We recommend that the feed is checked and if needed modified at least once a year
e.g. during the yearly maintenance performed by the service staff.
The Printer
2-10 Adjusting the printer feed
Service Manual - PlateWriter™ 2000 1545