Glunz & Jensen PlateWriter 3000 User manual

Service Manual
PlateWriter™3000/8000

Service Manual
PlateWriter™ 3000/8000
Edition AA, June 2014
This book has part No 10075832
T11296

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
© 2010 Glunz & Jensen A/S. All rights reserved.
Service Manual - PlateWriter™ 3000/8000 1425
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1425 Service Manual - PlateWriter™ 3000/8000
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 ..........................................2-1
Installing ink cartridges ...........................................2-2
Printer adjustment and set up ........................................2-3
Disabling of auto nozzle check ......................................2-3
Initial adjustment of print bed/print plane ..............................2-4
General....................................................2-4
Measuring input side height .....................................2-4
Measuring exit side height.......................................2-5
Adjustment procedure .........................................2-5
Print head initial height and print head protection adjustment ................2-6
Initial print head height adjustment ................................2-6
Print head protection adjustment ..................................2-7
Print head slant (CR)/bias adjustment.................................2-8
Resetting bidirectional setting in printer ..............................2-10
General...................................................2-10
Print an “adjustment variables” status sheet from the printer..............2-11
Bidirectional setting utility......................................2-12
Verifying and changing the bidirectional settings for the narrow platen gap . . . 2-12
Changing the bidirectional settings in the printer ......................2-14
Verifying and changing the bidirectional settings for the standard platen gap. . . 2-15
Final verification for the bidirectional settings ........................2-15
Fine adjustment of print head height and tilt ...........................2-16
Head height and tilt adjustment ....................................2-17
Tilt adjustment .............................................2-19
Head height for left and right side adjustment ........................2-20
Head height ...............................................2-20
Adjustment of print head height and tilt ............................2-21
Adjustment of print plane ......................................2-21

Service Manual - PlateWriter™ 3000/8000 1425
Table Of Contents
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Front registration system adjustment ..............................2-22
Side registration system adjustment .................................2-24
Adjustment of the printer feed .....................................2-26
Bidirectional fine tuning .........................................2-28
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 3000 .........................3-2
Recommended parameters setting for PlateWriter 3000..................3-4
Default parameters setting for PlateWriter 8000 .........................3-5
Recommended parameters setting for PlateWriter 8000.................3-10
Commands ....................................................3-11
Diagnostic Input...............................................3-11
Input sensors: ..............................................3-12
Diagnostic Output .............................................3-14
Diagnostic Current .............................................3-14
Adjustments....................................................3-15
Plate temperature settings (BE) ....................................3-15
Adjusting temperature settings...................................3-15
Gum/water replenishment settings (GR) ..............................3-15
Firmware update ................................................3-16
Procedure ...................................................3-16
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 PW3000/8000 .........................4-18
Launching the RIP for the first time .................................4-20
Configuring the RIP ............................................4-24
Activating the color proofing option .................................4-27
Epson proofing activation ......................................4-27

1425 Service Manual - PlateWriter™ 3000/8000
Table Of Contents 0-5
Part 5a:Spare parts for PW3000....................................5-1
Finding a spare part .............................................5-1
Ordering a spare part ............................................5-1
Original printer spare parts ........................................5-1
Part 5b:Spare parts for PW8000...................................5-24
Appendix A: Electrical diagrams for PW3000 ........................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
Appendix B: Electrical diagrams for PW8000 ........................B-1
Main power distribution ............................................B-2
Low voltage wiring ................................................B-4
Sensors, switches, LEDs and motors .................................B-4
Printer plane ....................................................B-6
Wiring schematic ...............................................B-6

Service Manual - PlateWriter™ 3000/8000 1425
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1425 Service Manual - PlateWriter™ 3000/8000
Table Of Contents 0-7

Part 1: Introduction
About this manual
Intended use of this manual
•This manual describes how to install software and firmware to the PlateWriter 3000
or PlateWriter 8000 system. The procedures described in this manual require a rea-
sonable level of technical 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.
1425 Service Manual - PlateWriter™ 3000/8000
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™ 3000/8000 1425
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.
1425 Service Manual - PlateWriter™ 3000/8000
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Introduction
The Functional description of the PlateWriter system
T11312
3
2
1

Service Manual - PlateWriter™ 3000/8000 1425
1-4 Introduction
The Functional description of the PlateWriter system

Part 2: The Printer
Initial startup of PlateWriter
•Remove all the packing materials and tape. Check carefully for all the tape inside
and outside the printer
"After removing packing materials, touch a metallic part of the printer to
prevent generating static electricity.
•Pull the protective material out of the print head.
1425 Service Manual - PlateWriter™ 3000/8000
2-1
The Printer
Initial startup of PlateWriter
2
T11251

Installing ink cartridges
•Press the power button to turn on the
printer.
•When REPLACING INK CARTRIDGE
INSTALL INK CARTRIDGE flashes on
LCD display, then press button, se-
lect OPEN RIGHT COVER and press
button. Approximately after 20 seconds the
ink cover is unlocked and slightly opened.
•Open the ink compartment cover by hand
fully.
•Remove each fluid cartridge from its pack-
age.
#Do not touch the green IC chip on the
side of the ink cartridge. Doing so
may prevent normal operation and
printing.
•Install the 2 x Liquid Dot and 3 x Mainte-
nance Fluid cartridges in the printer ac-
cording to the label on the inner side of the
ink cover as shown. Hold each cartridge
with the green IC chip facing up and point-
ing to the rear of the printer, and then in-
sert it into its slot as far as it will go until it
clicks. Liquid Dot and Maintenance Fluid
cartridges can in principle be placed in any
slot. We recommend to place Liquid Dot in
slot 3 and 4 (PK and Y) and the Maintenance Fluid into slots 1,2 and 5. After ink has
been charged the cartridges should normally remain in their respective positions.
They can be moved in case of e.g. nozzle loss, please refer to the user manual for in-
structions on how to do this. The RIP is default setup to use ink channel Pk and Y, if
other channels are used then the PlateWriter device setup has to be changed accord-
ingly.
"Small labels in the ink compartment cover can be moved to indicate which
slots currently has Liquid Dot and maintenance Fluid installed.
•After installing all 5 cartridges, close the ink compartment cover. The printer begins
charging and CHARGING INK flashes on LCD display. Follow the instructions on
the display.
$Stay with the PlateWriter during the charging process. Charging takes about
10 minutes. Never turn off the printer, open the top cover, open the ink
cartridges cover or remove the maintenance tank while the CHARGING INK
is flashing on LCD display, or you may damage the printer.
When PAPER OUT, LOAD PAPER flashes on the LCD display, charging is complete.
Press the tbutton repeatedly until appears on LCD display instead of a roll.
$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.
Service Manual - PlateWriter™ 3000/8000 1425
2-2 The Printer
OK
T11236
T11237
CLICK

Printer adjustment and set up
The following items needs to be checked and adjusted during the installation of the
PlateWriter.
•Disabling of auto nozzle check
•Initial adjustment of print bed/print plane
•Print head initial height and print head protection adjustment
•Print head slant (CR)/bias adjustment
•Resetting bidirectional setting in printer
•Fine adjustment of print head height and tilt
•Front registration system adjustment
•Side registration system adjustment
•Adjustment of the printer feed
•Bidirectional fine tuning
Disabling of auto nozzle check
If the auto nozzle check is enabled, then the printer will try to detect if all nozzles are
working. Because the Liquid Dot ink is not consistently detected, then repeated cleans
will be performed and eventually result in an error message from the printer.
The auto nozzle check should be switched off in the printer by selecting:
PRINTER SETUP -> AUTO NOZZLE CHECK -> OFF.
1425 Service Manual - PlateWriter™ 3000/8000
2-3
The Printer
Printer adjustment and set up

Initial adjustment of print bed/print plane
General
The print bed has been setup from the factory and does not normally require any
adjustment. The print bed must be adjusted if it has been removed and reinstalled. It is
however recommended to do a basic verification on the adjustment during installation.
The print bed is adjusted in each of the four corners by means of the pointed
screws (1). The print bed is secured by the two retaining screws (2).
The height of the print bed in the input side is measured against the feed roller shaft
(4). The height of the print bed in the exit side is measured as the difference between
the height of the print bed at the input side compared to the output side.
Measuring input side height
The height is measured on the input side as shown in the picture. Note that the
backside of the caliper is resting against the print head carriage shaft (3).
Service Manual - PlateWriter™ 3000/8000 1425
2-4 The Printer
Printer adjustment and set up
Left side
Right side
3
4
3
Input side Exit side
a
c
b
c=b+0.1 to 0.3 mm

Measuring exit side height
The exit side height is measured from the print bed to the underlying support as
shown in the picture.
Adjustment procedure
•Adjust one side at a time, left side or right side.
•Loosen the retaining screw (2).
•Adjust the two pointed screws (1). Turning clockwise will increase the print bed
height.
Turning counter clockwise will decrease the print bed height. Not that this may not
be measurable before the retaining screw is tightened.
•First adjust the input side height relative to the feed roller shaft (3).
•Then adjust the exit side by measuring the distance band cand calculating the dif-
ference.
•Tighten the retaining screw (2). It is important to tighten gently (app. ½ turn after
screw head have contact with print bed), not to deform the print bed.
•Verify the measurements, as they may change slightly when the retaining screw is
tightened.
•Repeat the procedure for the other side.
Always verify both sides are correct after the adjustment has been finished.
1425 Service Manual - PlateWriter™ 3000/8000
2-5
The Printer
Printer adjustment and set up
input side exit side

Print head initial height and print head protection adjustment
The initial adjustment of the print head height is done to ensure that the print head
will not touch the plate during printing.
The print head protection is a physical guard and a sensor that will help prevent that
dented or otherwise distorted plates will touch the print head during printing. The
guards are protecting the edges of the print head from contact with the plate. The
sensor will stop the printing and thus the movement of the print head if it touches the
plate during printing.
"Carefully examine the plate before printing. It should be flat and without
dents. The print head protection will normally protect the head and stop
printing before any damage to the head occurs. However, it cannot be
guaranteed that all problematic plates will be detected.
Initial print head height adjustment
Start printer in Serviceman Mode by pressing the
while pressing u,q, and button
simultaneously. Hold the three keys pressed until
the menu appears in the display.
Uncap the print head by selecting MENU ->
MECHA ADJUSTMENT ->
TEMPORARY PG -> [ENTER] UN CAP.
Open the printer cover and pull the printer carriage
out to access to head height camshaft gear as
shown below.
Turn the camshaft clockwise by hand and note that
the head height changes. Repeat until the highest
head height has been reached. Turn the camshaft 1
notch more clockwise. The headheight is now at
the 2. highest position.
Service Manual - PlateWriter™ 3000/8000 1425
2-6 The Printer
Printer adjustment and set up
Head height
right side
Head height
left side
Media feed
direction
OK
·The height adjustment gear on side of the carriage is
adjustable in five levels.
·1 st. level, WIDEST is as shown on picture when mark
on gear is at top. By turning the gear you can see and
check this.
§By turning clockwise from level
WIDEST,
§nextlevelwillbeWIDER,
§next level WIDE,
§next level STANDARD,
§next level NARROW, turning one more
level will return to WIDEST

Place the adjustment plate on the print plane.
Move the print head carriage carefully so that it passes over the adjustment plate
(no. 31) from the tool box as shown. Look in from the exit side of the printer and check
that the head can be moved over the plate.
"The print head is fragile. Take care not to force the print head over the
adjustment plate if the head height is too low. Take care not to push the print
head carriage downwards towards the print plane. This can potentially make
the print head touch the print plane and damage it.
The head tilt may be set to approximately the center of the scale. The final adjustment
of the print head tilt angle will be done later using a print job.
If the head height is not correct
loosen the screw for the head
height lever cams on each side
of the print head carriage. The
head height is changed by
moving the head height levers
up or down. Adjust the print
head so that print head
protection guards just touch the
adjustment plate. The final
adjustment of the print head
height will be made later using
a special print job.
Print head protection adjustment
Use a long screwdriver to adjust the print head protection sensor so that it touches the
adjustment plate slightly harder than the print head guards (see picture above).
1425 Service Manual - PlateWriter™ 3000/8000
2-7
The Printer
Printer adjustment and set up
Print head protection
sensor
Print head protection
guards
Head height levers Head tilt levers