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Service Manual

PlateWriter™ 3600 Pro

Service Manual

PlateWriter™ 3600 Pro

Edition AE, February 2017

This book has part No 10081554

T11435

This manual is published by: GLUNZ & JENSEN A/SSelandia Park 1

DK-4100 Ringsted

Denmark

Phone:+45 57 68 81 81

E-mail: [email protected]

Internet: www.glunz-jensen.com

© 2015 Glunz & Jensen A/S. All rights reserved.

Service Manual - PlateWriter™ 3600 Pro 1706

0-2

1706 Service Manual - PlateWriter™ 3600 Pro

Table Of Contents0-3

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

Initial adjustment of print bed/print plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Measuring input/exit side height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Print head height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Print head height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Print head slant (PF)/tilt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Print head slant (CR)/bias adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Front registration system adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Adjustment of the printer feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Controls of the PlateWriter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Part 3: The Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Connection the FU to the RIP PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Windows 7: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Parameters setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Default parameters setting for PlateWriter 3600 Pro . . . . . . . . . . . . . . . . . . . . . . 3-2

Recommended parameters setting for PlateWriter 3600 Pro . . . . . . . . . . . . . . . 3-7

Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Diagnostic Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Input sensors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Diagnostic Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Diagnostic Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12


Table Of Contents0-4

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Plate temperature settings (BE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Adjusting temperature settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Gum/water replenishment settings (GR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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 PW3600 Pro. . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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

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 3600Pro system. The procedures described in this manual require a reasonable level oftechnical 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 causedby unintended use of the equipment:

• As the equipment is certified by accredited test laboratory (UL International DemkoA/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, andCE certification of the equipment shall be removed as the certification will no longerapply 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 tocarry 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.


1-1Introduction

About this manual

Notes, cautions, and warnings !

Throughout the manual notes, cautions, and warnings are written in bold like theexample 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


information in the order to avoid any mechanical or

electrical damage to the equipment.

� Warning


information in the order to any personal injury.

Chemicals

• It is responsibility of the owner of this equipment that data is available to concerningpossible 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 themachine must be made according to local regulations. For recycling purposes signifi-cant components are marked with material specification according to the ISO 11469standard.

Service assistance

• If help is needed to correct any problem with the equipment, please contact yourlocal supplier.


1-2Introduction

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-platesprinting 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 platformA customized workstation accessible by both Mac and PC computers, loaded withthe 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 producepress-ready plates, e. g.: curing, gumming and drying of the plates after they areimged in the engine.


1-3Introduction


T11312

1

2

3


1-4Introduction


Part 2: The Printer

Initial startup of PlateWriter

• Remove all the packing materials and tape. Check carefully for all the tape insideand outside the printer

�After removing packing materials, touch a metallic part of the printer toprevent generating static electricity.


2-1The Printer


Installing ink cartridges

• Press the power button to turn on theprinter.

• Open the ink compartment cover by handfully.

• Remove each fluid cartridge from itspacage.

�Do not touch the green IC chip on theside of the ink cartridge. Doing somay prevent normal operation andprinting.

• Install the 2 x Liquid Dot and 2 x Maintenance Fluid and 1 x empty cartridges in theprinter according to the label on the inner side of the ink cover as shown. Hold eachcartridge with the green IC chip facing up and pointing to the rear of the printer,and then insert it into its slot as far as it will go until it clicks. After ink has beencharged the cartridges should normally remain in their respective positions.

�Small labels in the ink compartment cover can be moved to indicate whichslots currently has Liquid Dot and maintenance Fluid installed.

• After installing all 5 cartridges, close the ink compartment cover. The printer beginscharging and CHARGING INK flashes on LCD display. Follow the instructions onthe display.

�Stay with the PlateWriter during the charging process. Charging takes about10 minutes. Never turn off the printer, open the top cover, open the inkcartridges cover or remove the maintenance tank while the CHARGING INKis flashing on LCD display, or you may damage the printer.

�Always turn off the printer using the power button. Then wait until the LCDdisplay turns off. This ensures that the print head is safely capped.


2-2The Printer


T11236

Printer adjustment and set up

The following items needs to be checked and adjusted during the installation of thePlateWriter.

• Initial adjustment of print bed/print plane

• Print head height

• Print head slant (PF)/tilt adjustment

• Print head slant (CR)/bias adjustment

• Front registration system adjustment

• Adjustment of the printer feed


2-3The Printer


Initial adjustment of print bed/print plane

General

The print bed has been setup from the factory and does not normally require anyadjustment. The print bed must be adjusted if it has been removed and reinstalled. It ishowever recommended to do a basic verification on the adjustment during installation.

The print bed is adjusted and secured by the eighteen screws (1).

Measuring input/exit side height

The height is measured on the input/exit side from the printer base (2) to the top of theprint bed (3) by using the caliper (4) as shown in the picture.

�Distance from the printer base to the print bed on the input side must be 30,0±0,2 mm and on the exit side must be 30,5 ±0,2 mm.


2-4The Printer


input side exit side

2

4

3

2

41

3

Adjustment procedure

• Adjust one side at a time, input side or exit side.

• Install the adjustment tool (2) as shown on the picture below.

• Align the measuring tool (2) to the first screw (1) on the right/left side of the printbed and set it to 0.

• Move the measuring tool (2) to the next screw (1) and adjust the screw until thepointer is on 0 +/- 0.05, then do the same procedure to the all screws (1) in row.

• Turning the screw (1) will increase/decrease the print bed height.

• It is important to tighten gently (app. ½ turn after screw head have contact withprint bed), not to deform the print bed.

• Adjust the watcher on measuring tool (2) to exit side and repeat the procedure forthe other side as shown on the picture below.

• Insert the 0.15 mm plate to visually check if the plate is loaded smooth to preventany damage.

�Always verify both sides are correct after the adjustment has been

finished.


2-5The Printer


2

2

1

2

Print head height

The adjustment of the print head height is done to ensure that the print head will nottouch the plate during printing.

�Carefully examine the plate before printing. It should be flat and withoutdents. However, it cannot be guaranteed that all problematic plates will bedetected.

Print head height adjustment

• Start printer in Serviceman Mode by pressing the while pressing , , and

button simultaneously. Hold the three keys pressed until the menu appears inthe display.

• Remove the right upper cover.

• Load a 0.15 mm plate.

• Set te APG cam to the narrow or standard position as shown on the pictures below.

Adjustment settings

Scenarios Settings used for adjustments RIP

settings

Scenario Plate

gauges

Optimized

for

Plate

gauges

needed for

adjustment

Head

height

position

Head

height

(mm)

Head

height

position

10.15 0.15 0.15 Narrow 0.60 mm Narrow

0.30 Standard

20.20 0.20 0.20 Standard 0.60 mm Standard

0.30 Standard

3 0.15 0.15 0.15 Narrow 0.6 mm Narrow

4 0.20 0.20 0.20 Standard 0.6 mm Standard

5 0.30 0.30 0.30 Standard 0.6 mm Standard


2-6The Printer


Menu

OK

- -

Mark for narrowposition on the top

APG cam

-

Mark forposition on the top

standard

APG cam

• Uncap the print head by selecting Mecha Adjustment -> CR Un Cap -> Enter oruncap as described on page 2-12 (rawprint).

• Move the CR unit to the left end of the printer and remove the CR cover.

• Loosen the screw that secures the adjustment knob as shown on the picture below.

• Visually adjust the tilt of the print head to follow the direction of the loaded plate.

• Tighten the screw to secure the adjustment of the adjustment knob.

• Remove the plates as shown on the picture below.


2-7The Printer


Screw Adjustment knob

Plus (+)direction Minus (–)

direction

PRINTHEAD

PRINT BED FEED ROLLER

PLATE

PAPERFEED

DIRECTION

PRINT HEAD1.

2.

PRINT HEAD1.

2.

PLUSDIRECTION

MINUSDIRECTION

ADJUSTMENTKNOB

ADJUSTMENTKNOB

Plates

• Loosen the platen gap adjustment screws that secure the platen gap adjustmentlevers as shown on the picture below.

• Align the 0.6 mm feeler gauge to the right side of the print head, move the rightplaten gap adjustment lever up or down to make sure that there is a gentle contactbetween the feeler gauge and the print head (see picture below), secure the rightplaten gap screw and repeat the procedure for the left side of the print head.

�Perform the head height check, and make sure that the 0.7 mm feeler gaugewill NOT be inserted.


2-8The Printer


PG adjustmentlever

PG adjustmentscrew

PRINTHEAD

PRINT BED

PLATE(0.15 - 0.30 MM)

FEELER GAUGE(0.6 MM)

LEFT SIDE RIGHT SIDE

Print head slant (PF)/tilt adjustment

• Load a 0.15, 0.2 or 0.3 plate, depending on the selected adjustment scenario. Smallerformats should be loaded in landscape by using the front register pins.

• Start the program PW3600 Services tool.exelocated at C:\ GJ Tools \PW3600 Pro Service Tooland click Service tab. The head slant (PF)/tilt isadjusted by clicking on TILT Pk/Y (PF).

• The test job for the slant/tilt (PF) contains of a series of lines 1-8 and this is repeatedacross the plate.

• Each line contains a series of lines closetogether and then 1 single lines that aresupposed to be as close as possible tothe series of lines. Locate the single linethat is closest to the series of lineswithout touching them. The thin linehas to be parallel with the series of lines,if not the angle of the head is incorrect.


2-9The Printer


PW3600Pro Head Slant PF (tilt) test job.VSD4, head height/platen gap: Standard.Use for 0.15mm, 0.20mm and 0.30mm plate.

• If the line is not strait, the lever for thehead slant (PF)/tilt has to be moved upor down. Please note that adjustment ofthe tilt will change the general headheight and this has to be readjustedafterwards. The illustration showswhich direction to move the lever.

• E.g. if number 7 is correct then check the other number 7 across the plate, as theyalso have to be parallel. If not the printing plane/printbed is not adjusted correctly.However the tolerance on this is ±1, meaning number 7 could be correct in left sideand then number 8 in right side.

• To adjust the head slant (PF)/tilt go to programPW3600 Services tool.exe located at C:\ GJ Tools\PW3600 Pro Service Tool and click Service tab.The head slant/tilt is adjusted by clicking onUncap Printhead.

• Pull the printer carriage out to access the headslant.

• Loosen the screw that holds the head slant lever.Pull it up or down and tighten the screw again.

• Recap the head again go to Cap Printhead andclick on it.

• Recheck the head slant (PF)/tilt by printing anew plate following the steps above again.


2-10The Printer


Print head slant (CR)/bias adjustment

The bias adjustment is for adjusting the print headangle in the CR direction (carriage).

• Load a 0.15, 0.2 or 0.3 mm plate. This adjustment can also be done by using a pieceof coated paper.

• Start the program PW3600 Services tool.exelocated at C:\ GJ Tools \PW3600 Pro Service Tooland click Service tab. The head slant (CR)/bias isadjusted by clicking on BIAS Pk/Y (CR).

The test job for the head slant (CR)/bias consists of identical rows across the page. Thetest pattern should be aligned when the adjustment is performed correctly. Thereference line and the adjustment line should be aligned perfectly when slant isadjusted correctly.


2-11The Printer


Head bias

Media feeddirection

reference line

adjustment line

• To adjust the head slant (CR)/bias go to program PW3600 Services tool.exe locatedat C:\ GJ Tools \PW3600 Pro Service Tool and click Service tab. The head slant/biasis adjusted by clicking on Uncap Printhead.

• Open the top cover and remove both side panels.

• Move the CR unit to the left end on the printer and remove the CR cover byloosening the screws as shown on the picture below.

• Loosen the three screws (A, B, C) that secure the DAMPER KIT.

• Loosen the three screws (D, E, F) that secure the head holder.

• Loosen the screw (G) (Bit No. 1) that secures the adjustment knob as shown on thepicture below.

�Be careful not to completely remove the screw that secures the adjustment knob.


2-12The Printer


CR Unit

CR Cover

• Turn the adjustment knob either clockwise or counter clockwise to correct the headinclination as illustrated below.

�If using M1C1 or M2C2 bias the adjustment is 10 clicks off, if using PK1Y1 orPK2Y2 the adjustment is 15-20 clicks off.

• Tighten the screws and close the top cover.

• Recap the head again go to Cap Printhead and click on it.

• Print the adjustment pattern again and check the adjustment result. Repeat the stepsabove until the adjustment are finished. After finishing the adjustment, turn the unitOFF and then ON to cap the head or cap the head from service program.

�When the mechanical adjustments have been performed it’s advised to do acleaning from the control panel, as the head has been uncapped for a period.


2-13The Printer


Front registration system adjustment

• Load a 0.15, 0.2 or 0.3 mm plate, depending on the selected adjustment scenario.Smaller formats should be loaded in landscape so that the front register pins areused.

• Start the program PW3600 Services tool.exelocated at C:\ GJ Tools \PW3600 Pro Service Tooland click Service tab. The front register isadjusted by double clicking on Regist. Adjust.

• When the plate is printed, measure the distances d1 (left side) and d2 (right side) fromthe edge of the plate to the marks printed on the plate as shown on the picture.

If d1 and d2 are different, then open the printer top cover and remove the dryer.• Adjust the front registration pins by loosening the screws and turning the wheels

clockwise/counter clockwise as shown on the pictures below.

• Repeat the procedure until the d1 and d2 are similar.


2-14The Printer


d1 d

2

T11267

Feed direction

If d1 and d2 are similar, measure the distances d3 (left side) and d4 (right side) betweenthe marks printed on the plate as shown on the picture.

If d3 and d4 are different, then open the cover under the input table and adjust theprinter's small input table by loosening the screws (a) and turning the screws (b)clockwise/counter clockwise as shown on the pictures below.

Repeat the procedure until the d1 and d2 are similar.


2-15The Printer


T11267

d4

d3

Feed direction

a b

Adjustment of the printer feed

The feed adjustment needs to be done in order to secure the correct image length onthe plate. The printer already has a feed adjustment built in but since the correctiondepends on the plate thickness the correction value must be set in the page setup. Thismakes it possible to ensure perfect feed for all plate gauges used.

• Load a plate in portrait on the PlateWriter 3600 Pro. Note that the feed adjustmenthas to be done for each plate thickness.

• Start the program PW3600 Services tool.exelocated at C:\GJ Tools\PW3600 Pro Service Tooland click Service tab. The printer feed is adjustedby clicking on Feed Adjust.

• After the job has been printed place a ruler on the best line of fit.

• Measure the longest possible line 250,450 or 600 mm and find the deviationfactor as shown. In this case the feedneeds to be adjusted +0,16% measuredat the 25 cm point.


2-16The Printer


• Open the page setup(s) with plate gauge identical to the one performed for theabove test and key in the new value in the Feed adjustment in the "Configure De-vice".

The feed on different plate thicknesses might be different so if other plate thicknessesare used you must run the same test again using the corresponding plate. If the valueturns out to be different you can key in the value in the relevant page setup(s).

We recommend that the feed is checked regularly depending on the system usage.


2-17The Printer


Controls of the PlateWriter

It is possible to transmit simple commands to the PlateWriter in order to performcleaning, nozzle test, cap/uncap and fine adjustment of the print head, registrationand feed.To send a command to the PlateWriter 3600:

• Start the program PW3600 Services tool.exe located at C:\GJ Tools\PW3600 ProService Tool and click Service or User tab. The files are located at C:\GJTools\PW3600 Pro Service Tool\Test jobs\PW3600Test or PW3600 pro funktions.

• Select PW 3600 as printer, select the command and double click on it and theselected command will be transmitted to the PlateWriter unit.

Command Description

CL1 Clean PKY Performs a SMALL clean on Black and Yellow ink channels. Typically

channels with Liquid Dot.

CL1 Clean CM Performs a SMALL clean on Cyan and Magenta ink channels.

CL3 Clean PKY Performs a MEDIUM clean on Black and Yellow ink channels.

Typically channels with Liquid Dot.

CL3 Clean CM Performs a MEDIUM clean on Cyan and Magenta ink channels.

Uncap Print head will be released from maintenance station and can be

moved sideways.

Uncap and move Print head will be released from maintenance station and

automatically moved to opposite side of the printer and turned off.

This function is used when manual clean of print head are needed.

Cap The will be moved back and locked on the maintenance station (if

uncap.prn was used prior).

Nozzle Nozzle test will be printed if plate or paper is loaded into the machine.

Weekly clean Performs a clean of the ink system.

Feed adjust Prints a feed job for adjustment of the printer feed.

TILT Pk/Y (PF) Prints a test job for the slant/tilt (PF) adjustment.

BIAS Pk/Y (CR) Prints a test job for head slant (CR)/bias adjustment

Regist. adjust Prints a test job for adjustment of register pins


2-18The Printer


Jet QA Prints an advanced nozzle test

Printer Select your PW3600 device listed before printing

Maintenance

It is recommended to run Weekly clean bi-weekly e.g. at the end of a working week. Itis also recommended to do this before longer breaks (holiday seasons etc.) in plateproduction. This is to prevent sediments of ink in cap and tubes.

It is recommended to perform a manually cleaning of print head once a month. Asdescribed in Operating manual.


2-19The Printer



2-20The Printer


Part 3: The Finisher

General

The Finisher is designed to cure and dry the Liquid Dot (LD) that is jetted onto theiPlate by the imagine unit. It also applies iFinisher to cover and protect the iPlate. Theheating of the plate together with iFinisher application will ensure a clean backgroundof the iPlate when set on press.

When the iPlate is placed over the optic sensor in the front belts the belts will start tomove the plates into the oven. When the oven sensor is activated by the iPlate thespeed of the belt and temperature of the oven is regulated to get the correcttemperature on the plate.

The iFinisher pump will start recycling so that iFinisher is applied to the rubber rollersvia the PUR application roller.The Finisher is also controlling the ink dryer inside/on top of the imaging unit. Plateregistration is also controlled from the Finisher if applicable.

Connection the FU to the RIP PC

Windows 7:

Run the PTTY SW and select appropriate comport.


3-1The Finisher

General

Parameters setting

Default parameters setting for PlateWriter 3600 Pro

�The defaukt settings are NOT recommended settings, but the default valueswhen Finisher Unit Firmware is installed.See the recommended values for PlateWriter 3600 Pro on page 3-7.

Para-meter

Description Min. Max.DefaultCFG=1

CFG=2 CFG=3 Unit Explanation

CFG ConFiG 0 4 0 0 0 Reset all parameters to

factory defaults:

1: PW2000, PW2400.

2: PW3000.

3: PW8000.

4: PW3600Pro.

OVS OVen

Systems

1 2 1 2 2 OVS=1: Oven with 4

bulbs.

OVS=2: Oven with 5

bulbs sets.

IDS Ink Drier

System

1 2 1 2 2 1: Original ink drier

with air fan and heater

(PW2000/PW2400).

2: Heat in print plane,

input table and small

fan next to print head.

BWS Backside

Wash

System

1 3 1 1 2 1: Disabled, old wiring

2: Disabled, new wiring

3: Enabled and new

wiring

RGS ReGister

System

0 3 0 0 0 0: No registration

system.

1: Side register only.

2: Front register only.

3: Front and side

registers.

DAO Drier

Always On

0 1 0 0 0 bool Activate ink drier

permanent.

DFS Drier Flow

Setting

20 100 80 100 100 % Duty cycle for the ink

drier fan or fan next to

the print head.

DHS Drier Heat

Set point

15 55 28 40 22 °C Temperature for ink

drier. If IDS=2 this

controls the printer

plane temperature.

DHB Drier Heat

Beta

-200 200 -40 0 0 0.1°C Calibration offset for ink

drier temperature

sensor (print plane if

IDS=2).


3-2The Finisher

Parameters setting

Para-meter



FIC Fluid In Cap

0 550 0 0 50 Maximum amount of

strokes before the

pump of the fluid in cap

system will go into error

mode.

1AL P1 ALpha 0 500 160 160 160 Alpha value for heat

regulation.

1BE P1 BEta 0 500 180 180 180 Beta value for heat

regulation.

1FF P1 Front

Factor

0 200 140 140 140 % Compensation of curing

effect for front edge of

plate.

1RF P1 Rear

Factor


effect for rear edge of

plate.

1GR P1 Gum

Replenish

0 100 17 17 17 ‰ P1 Gum replenish

amount in permille of

process time.


regulation.


regulation.

2FF P2 Front

Factor



plate.

2RF P2 Rear

Factor



plate.

2GR P2 Gum

Replenish

0 100 17 17 17 ‰ Gum replenish amount

in permille of process

time.


regulation.


regulation.

3FF P3 Front

Factor



plate.

3RF P3 Rear

Factor



plate.

3GR P3 Gum

Replenish



time.


regulation.


3-3The Finisher

Parameters setting

Para-meter




regulation.

4FF P4 Front

Factor

0 200 140 140 140 % Compensation of

curing effect for front

edge of plate.

4RF P4 Rear

Factor



plate.

4GR P4 Gum

Replenish



time.


regulation.


regulation.

5FF P5 Front

Factor



plate.

5RF P5 Rear

Factor



plate.

5GR P5 Gum

Replenish



time.


regulation.


regulation.

6FF P6 Front

Factor



plate.

6RF P6 Rear

Factor



plate.

6GR 6 Gum

Replenish



time.

GRI Gum

Replenish

mInimum

0 120 5 5 5 sec Minimum amount of

replenish before

released.

GRA Gum

Replenish

mAximum

0 300 30 30 30 sec Maximum amount of

replenish before

replenish is given

between plates during

process.


3-4The Finisher

Parameters setting

Para-meter



GRD Gum

Replenish

Distance

100 1000 250 250 250 mm Minimum distance

between plates before

replenish is given.

FRS Front edge

Regulation

Start

0 500 100 100 100 mm

FRE Front edge

Regulation

End

0 900 200 200 200

RRS Rear edge

Regulation

Start

0 500 200 200 200 mm

RRE Rear edge

Regulation

End

0 900 300 300 300 mm

PWB PoWer Beta -500 -1 -230 -230 -230 Determines the relative

level of power when

max transport plate

speed is reached.

GAP GAP length

edge

regulation

0 240 200 mm

CUR CURrent

reference

heat

regulation

0 15000 8400 mA

STT StarT

Temperatur

e heat

regulation

0 250 60 60 60 °C Oven temperature

setting when FU is idle

and printer is printing.

PWC PoWer

Center

50 100 100 100 80 % Reduce power of center

bulb pair in oven to

lower the the plate

center temperature.

TSA Transport

Speed mAx

100 650 250 350 450 mm/

min

Max. transport speed of

the plate during curing.

TSP Transport

SPeed

5 50 15 cm/

min

Transport speed in

process P1-P3.

BEE BEEp 0 0xFF 1 1 1 Sound alert when: 0:

Off

1: When plate is ready

in printer.

2: When FU is ready.

3:Both.

AUT AUTo 0 1 0 bool


3-5The Finisher

Parameters setting

Para-meter



IRS Infra Red

Sensor

sensitivity

adjustment

0 5000 50 50 50 my

sec

Time that IR LED is on

prior to reading sensor

value. The higher the

value the higher the

sensitivity.

REG REGistratio

n system

timer

0 99 30 30 30 1/10

sec

Delays when

registration pins are

moved down after the

printer feed rollers are

down.

THS Table Heat

Set point

15 55 15 45 25 °C Temperature setting for

input table (Only used if

IDS=2).

DFT Drier Fan

Time

0 21600 15 10 10 s Time ink drier fan is

active after last printing

has been detected

(print head moving).

DHT Drier Heat

Time

0 21600 10 1800 1800 s Time heat in ink drier

print plane and input

table is active after last

printing has been

detected.

TSS Table

Standby

temperature

Set point

15 50 15 42 22 °C Standby temperature

for input table (Only

used if IDS=2).

DSS Drier

Standby

temperature

Set point

15 50 15 30 20 °C Standby for printer

plane.

PDT Pins Down

Timer

10 3600 300 300 300 s Time before front

register pins are moved

down. This is to

minimize the risk that

the finishing unit is

powered off with the

pins in up position. To

reactivate register pins

activate the printer feed

rollers once again.

BWE Backside

Wash

Engage

distance

0 150 50 50 50 mm Distance from plate

front edge to gum roller

when backside wash is

engaged.

BWR Backside

Wash

Release

distance

0 150 50 80 80 mm Distance from plate rear

edge to gum roller

when backside wash is

released.


3-6The Finisher

Parameters setting

Para-meter



TPW Total

PoWer

1000 3000 2500 2500 2500 W Power limit for oven

speed is reduced to

lower power

consumption.

OPW Oven

PoWer

1000 3000 2000 2000 2000 W Nominal power of all

bulbs in oven.

UPW input table

'Under' heat

PoWer

0 1000 0 300 500 W Actual power of input

table heat.

DPW Drier

PoWer

0 1000 750 400 500 W Actual power of ink

drier or print plane

heater.

PHP Print Head

Protection

0 1 0 0 0 bool Enables or disables

print head protection.

Recommended parameters setting for PlateWriter 3600 Pro

• Set CFG=4.

Then set the following parameters in order as shown:

• Backside WashBWS=2 Backside wash not mounted or disabled.BWS=3 Backside wash mounted and enabled.

• Register SystemRGS=0 No registration system.RGS=1 Side register only.RGS=2 Front register only.RGS=3 Front register and side registers.

• Print Head ProtectionPHP=0 No print head protection or disabled.PHP=1 Print head protection mounted or enabled.

Parameter PW 3600 Pro

RGS 2

CFG 4

BWS 2

PHP 0

FIC 150

DHS 35

DFS 75

DFT 15

DHT 10

IDS 1


3-7The Finisher

Parameters setting

• Type SAV (SAVe parameters) in the USB-Hyper Terminal Window, press the Enterbutton after the change of the last parameter to save the changes.


3-8The Finisher

Parameters setting

Commands

The following commands are used for diagnostics of the Finisher.

DEF DEFault parameters Set all parameters to their default values.

DIC DIagnostic Curren Test current sensor on oven in finishing unit.

DII DIagnostic Input Test system inputs.

DIO DIagnostic Output Test system outputs.

LPA List PArameters List all parameters and software version information.

SAV SAVe parameters Save all parameters to flash.

To run any of the above commands the Finisher must be in program “0” on the toggleswitch/program selector. Wait until the screen show the prompt “>” and then type thethree characters needed.

�If you type an error you cannot erase and retype. Simply press the Enter keyon the keyboard and the FU will reply with a “?” and a new “>”. Then tryagain.

Diagnostic Input

• Type DII and press Enter.The screen will start to show the state of the input sensors:


3-9The Finisher

Commands

Input sensors:

prog: toggle switch with program selected.convey.: optic sensor that detect the plate in the infeed of the FU.oven: mechanic switch that is placed at the very entry of the oven.oven temp.: shows the temperature of the plate curing oven.dry temp.: shows the ink drier temperature in 0,1 °C (26,4 °C).hex: N/A

prg: Program selection.ose: Oven State and Error, controlling the green and red LED.

non: Off (as in diagnostic).rdy: Ready.pcs: Process.pdp: Plate during process.pll: Plate is too short or too long.nrd: Not ready as in idle.por: Program selection is out of range.blb: Bulb error.mot: Motor error.

mst: Main State.idl: Idle.pcs: Process (P1-3).rin: Gum/rinse (P4).dia: Diagnostic (P0).err: Error.

gst: Gum State, only valid when Main State is pcs.wfr: Wait for front of plate to reach gum section.wrr: Wait for rear edge to exit rollers.wrg: Gumming, wait for plate exit gum.end: Plate has left unit.

rst: State of registration system.0: Start1: On its way towards home position.2: Waiting to be activated by lift up feed rollers.3: On its way towards upper position.4: Waiting to be de-activated by lift up feed rollers.5: Pins havent reached their home position in time, error waiting to be

de-activated by lift up feed rollers by user.6: Pins havent reached their upper position in time, error waiting to be

de-activated by lift up feed rollers by user.gap: Distance between consecutive plates for determing is replenish can be

given (mm).ovt: Oven temperature (°C).odc: Oven Duty cycle (%).sdc: Side compesation Duty cycle.reg: Actual compensation for regulation as in front and rearedge compensation(%)cur: Measured current as a percentage of nominal (%), used for compensation

for mains variations.count: Taco pulse count since plate entry.drt: Drier temperature (0,1 °C ).ddc: Drier duty cycle (%).dpc: Drier pass counter, indication of sensor for printer printing, head pass

(Times per second).


3-10The Finisher

Commands

pwm: PWM for transport motor (%).grb: Gum replenish bank, accumulated replenish (sec).utt: Under floor heater temperature in feed table (gen. III only).utd: Duty cycle of under floor heater (gen. III only).

More potential input sensors:

ost: Oven State, only valid when Main State is pcs.wfs: Wait for frontedge at oven sensor (switch not IR sensor).wmt: Wait for minimum temperature in oven.wfo: Wait for frontedge in oven.ref: Regulation for frontend of plate.ren: Regulation for center part of plate.rer: Regulation for rear end of plate.wfr: Wait for ready for next plate.end: Wait for ready for next plate.jst: Jog State, only valid when Main State is idl.nrd: Not ready, switch sensor covered without IR sensor.rdy: Ready.exi: Plate detected by IR sensor.

php: Print head statedis: Disabled.arm: Enabled and ready.stp: Print head is stopped (cover open), wait for feed roller to go up.wai: Waiting for feedroller to go down. (then go to ‘arm’ state)

When press Enter again the readout will change, so that it lists the same parameters aswhen in other programs than “0”. A header will indicate the parameters after each 10lines of print out.


3-11The Finisher

Commands

Diagnostic Output

• Type DIO and press Enter.The screen will start to show the transport motor test and readout the tacho signalfrom the main drive motor. It will continue to read out the tacho until Enter is pressedagain.

Next is the Test drier, where the ink drier temperature will be listed and the heater willbe powered on.

�Do not keep this one for a prolonged period. The heating element willcontinue to be one until the enter key is hit again.

Diagnostic Current

• Type DIC and press Enter.


3-12The Finisher

Commands

The values shown are in mAmps and as it lists ''Current 1'' through ''Current 4'' it willpower on one lamp at a time. The readout should collerate to the wattage of the lampsin the curring unit. (500 watt lamp will readout approx. 2500 at 220 volts, 400 wattlamp will readout approx. 2000 at 220 volts etc.)

Adjustments

Plate temperature settings (BE)

Attach thermostrips to the back of a plate and run it through the finishing unit using asuitable program (see the User Manual, Part 2: Daily use, Finishing).Check that the temperature is between 170 and 200 all over the plate.Adjust parameters 1BE, 2BE or 3BE depending on which program 1, 2 or 3 is selected.

�If the temperature is lower than the range mentioned above increase the valueby 5 or 10 and run the plate again with new strips. Repeat until temperature iswithin range for all plate gauges used.

Adjusting temperature settings

Adjust parameters 1BE, 2BE, 3BE, 4BE, 5BE or 6BE for PW 3600 Pro depending onwhich program 1-6 is selected. If the temperature on plate is too low decrease the valueby 10-20 and run the plate again with new strips. Repeat until the temperature iswithin range for all plate gauges used.Remember to type SAV to save temperature settings after they have been changed.

Gum/water replenishment settings (GR)

If the gum becomes thicker during the day it might be necessary to increase the GRvalue. Increase 1GR, 2GR, 3GR, 4GR, 5GR or 6GR (depending on which program 1, 2,3, 4, 5 or 6 value by 1 or 2 but keep close attention that the iFinisher does not becometoo thin. Check that the level in the iFinisher container actually decreases (and neverincreases) during a day’s production.


3-13The Finisher

Adjustments


3-14The Finisher

Adjustments

Part 4: RIP Installation

Overview

The installation procedure described in this chapter covers the following issues:

• Installation of the Epson SC-T5200 printer driver

• Connecting PlateWriter and proofer to the RIP workstation

• Installation of Navigator RIP

• Installation of plug-ins and manuals

• Launching and configuring the Navigator RIP

• Creating and calibrating a proofing Page Setup

Connecting the System and optional proofer to your RIP

workstation

Having charged the PlateWriter System with Liquid Dot (see "Hardware Installation"manual for details), you should already have it plugged into the mains.To complete the installation of the driver, you must connect your PlateWriter Systemto your computer.If you have also purchased the optional proofer, you should now go ahead and installthis, following the manufacturer’s instructions.

Epson 4880 & 7880 proofers only

Locate the Installation CD.Switch the printer on.Insert the ink cartridges and allow the printer to perform the ink charging cycle(about 10 minutes).Start the installation from the installer CD supplied by Epson with the system or youcan use the PlateWriter RIP 8 Installer DVD where the drivers for Epson 4880 and7880 also can be found.When the installation software starts to search for the printer, connect the proofer toyour RIP workstation.When it is installed, quit the installer and restart your workstation.


4-1RIP Installation

Overview

Installing the Navigator RIP for Windows

General

The Navigator RIP is installed on the RIP workstation delivered with the system.This workstation has been specifically configured to deliver the best performancepossible and includes Windows 7 (soon Windows 10), 4 GB of interleaved RAM, andabout 500 GB of available space on the hard drive after installation.Should the RIP not be installed on your RIP workstation or, if you for some reasonneed to reinstall it, the below described installation procedures outline the stepsnecessary for installation of the Navigator RIP, the Inkjet PlateMaking X1 plug-in, theiCTP proofing plug-in, the iScreen plug-in, a predefined RIP setup with limitedcalibration profiles, the user documentation and Acrobat Reader 9.

Before installing the Navigator RIP

Set up the PlateWriter hardware as described in the separate Hardware Installationmanual.

Overview

Installing and configuring the Navigator RIP for PlateWriter on Windows 7 consists ofthese basic steps:Installation of the RIP and dongle software.

�Do NOT plug in the USB dongle before you have completed installation ofthe dongle software.

Installation of the Inkjet PlateMaking plug-in, calibration profiles and the iScreenplug-in.If required, installation of the optional Epson proofing plug-in and the associatedEpson screening libraries.Installation of Adobe Acrobat Reader.Configuring of the RIP by printing GJ factory default file and entering passwords.


4-2RIP Installation


Installing the Navigator RIP, plug-ins and manuals

• Insert the PlateWriter Installer DVD into the RIP workstation.

• Locate the CD Drive and open it. Double-click the Platewriter Software 3.01 icon.


4-3RIP Installation


DVD RW Drive (E:) Platewriter 3.010 bytes free of 4.14 GBCDFS

DVD RW Drive (E:) Platewriter 3.01 Space free: 0 bytes File system: CDFS

CD Drive Total size: 4.14 GB

• Software Installer window appears.

• Click Next to continue on the Information window listing the available components.

• In the Select Components window you can choose Custom or Standard install. TheStandard install will select the most likely components to install.

• In general we recommend selecting the components from the Standard install, andthen you can add on additional components.

• Please refer to the list on the next two pages.


4-4RIP Installation


List of the components available for installation:

Categories Item Comments

Navigator Xitron Navigator RIP This is the main Navigator RIP application and

must be installed.

Dongle Driver Installs the Sentinel Dongle Driver and is required

to run the RIP.

G&J Password Utility Application to configure the passwords for iScreen

and PlateWriter Output Plug-in and must be

installed.

Calibration chart Test charts with predefined calibrations selected

based on the standards in the RIP.

Factory default Installs the file which can be activated in the RIP

to configure the memory settings, create some

sample Page Setups, and install a number of

preset calibration curves for different printing

presses. It is highly recommended to install it.

German/French interface Installs German/French user interface to the RIP.

Do not select this option when installing the RIP!

Plug-ins for

Navigator

Platewriter Output

Plug-in

Installation of this feature will enable the Inkjet

PlateMaking X1 plug-in forthePW2500/PW3000/

PW3600Pro/PW8000. This is required for the RIP

to communicate with the System and must be

installed.

CIP Plug-in Must be purchased as an option and is used to

control the ink level on press based on reading

from the RIP.

v-DOT II Glunz & Jensen includes a standard proofing

option for Epson 4880, 7880 and 9880 with the

iCtP system. For advanced proofing options you

will need to purchase ColorPro option.v-DOT III

Additional files GJ iPosition Copy the installer file for iPosition to the RIP hard

drive. If installed, the program will run a full time

limited version of the program. A dongle is

required to run the application.

GJ Wallpaper Installs Glunz & Jensen special wallpaper.

Sample files Sample files and test files in PDF.

PosiFlow 5 workflow

software

Software that makes possible to control the RIP

software from one or more remote computers and

set up different queues/actions.


4-5RIP Installation


Categories Item Comments

ExtremeZ 5.03 Software that provides printing connectivity across

platforms. The program is used for creating virtual

printers with AppleTalk or Bonjour protocols. Use

this to print directly from your Mac/PC to a

Spool/Hot Folder on your RIP PC.

ExtremeZ 6.03

ExtremeZ 7.1x14

Maintenance movies Video showing the maintenance of the

PW2000/2400/2500/3000 ink system.

Highly recommended!

TrapPro default settings Installs the default settings for trapping, when

using the TrapPro in the RIP.

Driver setup PW2000 printer driver Installs the printer driver to the selected variant of

the PlateWriter. The PlateWriter must be attached

doing the install to configure the correct USB port.PW2400 printer driver

PW3000 printer driver

PW3600 Pro printer

driver

PW8000 printer driver

Toolbox Product selector After selection of the RIP, is needed to select the

type of the PlateWriter, matched to the RIP.

Required to set up output plug-in.

PW adjust for

PW3000/PW8000

Software and print-files for the adjustment of the

PW3000/PW8000. Highly recommended to

complete the plate writer adjustment.

PW adjust for

PW 3600 Pro

Software and print-files for the adjustment of the

PW3600 Pro. Highly recommended to complete

the plate writer adjustment.

PWAdjust utility Adjustment utility for the PlateWriter 2000/2400

platform.

Raw Print adjust utility Software allowing to send print-files (prn.) directly

to the PlateWriter.

Epson net tool Software to configure the network card in the

PlateWriter image engine. Only used if you want to

connect the engine via Ethernet.

Windows PS driver For creating a Windows PostScript driver.

PPDs PPDs for Windows and Mac OS.

iCtP HyperTerminal Installs HyperTerminal settings to Windows used

to access the software of the finishing unit.

Adobe Reader For viewing the manuals and viewing PDF’s supplied

by customers for printing within the RIP. We

recommend to install this application.

Bonjour PS Install Bonjour for Windows to connect with

printing from the Windows platform.


4-6RIP Installation


• After selecting the components, confirm your choice by clicking Next.• Then press Install to continue.

• Navigator - InstallAware Wizzard window will appear, select product and clickNext to continue.

• Enter the password or just click Next.


4-7RIP Installation


• Click Next to continue.

• Click Next to begin the configuration.

• When the process is done, click Finish to close the wizzard.


4-8RIP Installation


• After the installation a dialogue box will appear to inform that the installation wassuccessful. Click Finish to continue.

• Select Destination Location for Plugin and iScreen box will appear, click Browse toselect folder.


4-9RIP Installation


• Select Navigator...

• Select Navigator 10.1r2 and click OK to continue.



4-10RIP Installation


• Modify setup box will appear, click Repair to continue.

• After the Setup is complete, click Close to continue.

• Ready to Install box will appear, click Install to continue the installation.




• After the PlateMake product selector box will appear, select PW3600 Pro in the Prod-uct selection row.

• Write the PlateMaking X1 password in window (see IJMPX1 code from the codesheet).

• Write the iScreen password in window (see iScreen code from the code sheet) andclick OK.




• A dialog box will appear to inform that the setup has finished installing PlateWriterPlugin and iScreen, click Finish to continue.

• A Select Destination Location for Factory Default files box will appear, click Browseto select folder.

• Select Navigator 10.1r2 and Factory default, and click OK.





• Installation of the Factory Default files on your computer started.

• Click Yes to continue.




• The Navigator box will appear, enter the 32-bit v10 password found on the donglelicence paper, click OK and go to Navigator-> Print File.

• Select Factory Default.

• Click Print.




• The PlateMake product selector box will appear, select PW3600 Pro and click OK.


• Click Finish.

Installation of the RIP is completed.




Renaming the Epson printer to PW3600 Pro

For the RIP to see the PlateWriter, it is needed to rename the previously installedEpson SC-T5200 printer driver to PW3600 Pro:

• Select the Windows Start button in the bottom left corner of the screen, then selectDevices and Printers.

• The Devices and Printers window will appear.Right click on the Epson SC-T5200 printer, and from the appearing menu selectPrinter properties.

• The Epson SC-T5200 Properties window will appear.




T520

Epson SC-T5200

Epson SC-T5200 Properties

Epson Stylus Pro 4880

• The printer name becomes selected, now rename the Epson SC-T5200 printer toPW3600 Pro and press Ok.

• The printer name is changed.




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 "SuperPro, 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 InterfaceLanguage.

• Select English (United States). This is the keyboard map for the keyboard suppliedwith RIP workstation.

• When selected the User Interface Language, the RIP will advise that it will need torestart.

�If the German user interface is installed, it can be enabled here. ChooseGerman, 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.




• The very first time the RIP starts, it will automatically run a start-up configuration.

• The Navigator splash screen will appear, and behind it is the main screen.The main screen is called the Throughput Window and it displays informationabout the RIP, settings, jobs and the overall status.

• In the Throughput Window you will see how much memory the RIP has allocated,the plug-ins installed, the RIP serial number and anything else that may be installed.This can be useful information when troubleshooting (determining versions ofplug-ins etc).




• Once the Splash screen has disappeared, the Output Controller/Monitor Windowwill appear (if it does not, press Ctrl + O).

The Output Controller/Monitor Window shows jobs that are in the queue and jobsthat have already been printed. It can be toggled On and Off by pressing the Ctrl + Okeys. Any time you click in the background, it will disappear and you will need totoggle Ctrl + O to make it reappear.

• In order to reduce the time it takes to set up and configure the RIP, we have presetsome settings in a file called GJ factory default. You will have to print this file.

• Click in the Navigator window to bring it to the front.

• Select Navigator -> Print File…• In the Print File window navigate to the folder C:\Xitron\Navigator 8.3r1\Factory

default. Double-click the folder to open it.




• Inside the Factory default folder...

...set Files of type to PostScript, PDF and XPS Files (*.ps,*.pdf,*.xps) and Page Setupto Default Page Setup.

• Select the GJ factory default file and click Print.• You will see text scroll down the Throughput Window.

Once it has finished, select Navigator -> Quit.• Restart Navigator RIP.

�Printing the GJ factory default file sets up the RIP’s Buffers, configures theMemory requirements, installs some Calibrations, Tone Curves (dot gaincurves), and Page Setups for various printing press types. Also printing thefile will provide most users with all the settings they need to start using theRIP immediately.

�Once the RIP has restarted you will need to enter your unlock codes beforeyou can start using the RIP.

• Run file: C:\Xitron\Navigator 8.3r1\Utilities\migrate\SW_Migrate\Migrate.exe.

• Select old and new RIP and click 'Migrate'.




• Click 'OK'.

• Click 'Yes' and the transfer is completed.




Configuring the RIP

�After printing the GJ factory default file, all security unlock codes for theplug-ins will be erased.Therefore when launching the RIP after printing the file you get several errormessages. This is normal and is due to the RIP trying to activate the device forwhich the codes have not been entered.The next step in configuring the RIP is to check that the buffer and memorysettings have been configured correctly by the GJ factory default file, then toenter the Security Unlock codes for your devices/plug-ins and to restart theRIP one last time to activate the devices/plug-ins so that all the settingsbecome active.

• Select Navigator -> Configure RIP.

• This opens the Configure RIP dialog.

Set Page buffering to Multiple (Parallel).Set Network buffer to 64.Set Printer buffer to 40000.Click on Options.




• This opens the Configure RIP Options dialog.

Set Disk space left for system to 500.Set Minimum memory left for system to 256,000.Click on OK to return to Configure RIP dialog.

• Click Extras…




• This opens the Configure RIP Extras dialog.

There are a number of passwords supplied with your system, not all are entered here.If you purchased the optional Proofing function or CIP3, these passwords will beadded separately later. For now you will need to enter the passwords for the Inkjet,PlateMakingX1 and for any other devices you purchased unlock codes for.

• Start by selecting the Inkjet, PlateMakingX1 item and click Add...Enter the corresponding password and click OK.

Repeat the procedure for any other features/devices you have codes for such astrapping or imposition.

• Finally click OK in the Configure RIP Extras and the Configure RIP dialog boxes tosave these changes.

• Select Navigator -> Quit to exit the RIP.

• All of the configurations and passwords have been saved.

• Restart the RIP to activate changes and unlock codes.




Activating the color proofing option

The iCtP System supports Epson color proofing by default. You will need to type inthe activation codes for this option.

There are three main Epson color printers that can be activated:

• Epson 4880• Epson 7880• Epson 9880

You should follow the instruction for activating the appropriate printer for the Epsonthat you have. You can purchase additional codes for activating other devices fromEpson or other manufacturers, such as Epson 4800, 7800 and 9800.

Epson proofing activation

• Select Navigator -> Configure RIP.

• This opens the Configure RIP dialog.

Click Extras…




• This opens the Configure RIP Extras dialog.

• Scroll down the list of features to the iCtP device X-Epson3, vDot-3. Click Add...• Enter the X-Epson3, vDot-3 activation code and click OK.

• Then click Add for activation of X-Epson3, vDot-3 Lite. Enter the X-Epson3, vDot-3Lite activation code and click OK.

• Finally click OK in the Configure RIP Extras and the Configure RIP dialog boxes tosave these changes.

• Select Navigator -> Quit to exit the RIP.All configurations and passwords have been saved, but the process has not beencompleted - see next page!




• Restart the RIP, then choose Navigator -> Device Manager.

• The Device Manager dialogue appears. If you previously have entered the pass-words correctly for X-Epson3, vDot-3 and Epson3, vDot-3 Lite, you will see this listappear when choosing Epson-vDot-II.i32 as plug-in.

Click on New…• The Device Manager Edit window will appear.




• In the Type drop-down menu you should see the Epson devices.

• Select 4880 Color vDot or 7880 Color vDot or 9880 Color vDot, depending on whichproofing device you want to add.

• Enter a name for the device.

We recommend that you use a name that clearly identifies the device, e.g. Epson 7800Color vDot.• Leave the Address field blank.

• Click OK.

• Now the Device Manager list will show the new device you have added.

• If you have added the device correctly, click OK to continue. The device is nowadded and ready to be selected in the Page Setup menu. The individual settings forthe device can be configured here.




• Configuring other devices than Epson 4880, 7880 and 9880 may require adding addi-tional codes. This is for example the case with Epson 4800, 7800 and 9800. Here youselect the menu Preview -> Select Device.

• The Select Output Device window appears.

Select the device and choose Select. This is an Epson 7800, which was added from theDevice Manager after installing the Epson vDot-2 plug-in. You will see the additionalEpson 7800 you just added.

• You can now select the device and then enter password.

• In the top menu bar you will see the item Preview has been replaced by Epson 7800.

Select this menu item and from the drop-down menu select Enter a Xitron Password...




• Enter the second password you were given for X-Epson2, vDot-2 and vDot-2 Litefor the Epson 7800. Click OK. Your Epson 7800 is now enabled.

• The Epson2, vDot-2 Lite passwords will be used for the Epson 4800 series and theX-Epson2, vDot-2 will be used for larger format Epson printers.

You have now completed the RIP installation. Please refer to the Operating Manual forinformation about creation of Page Setups and Print Queues.




Part 5: Trouble shooting

General

If the iCtP system does not work properly, refer to the following pages to find theparagraph that comes closest to your problem.

For cleaning and maintenance subjects see the iCtP system User's Manual.

The electrical diagrams are located in Appendix of this manual.

�To change a fuse, switch off all power to the processor first.

Always ensure that the new fuse is of the correct rating according to the

diagram.

Before starting troubleshooting

IMPORTANT

�Plates and finisher solution are very sensitive materials and correct storage isvital to obtain a satisfactory production result. Incorrect storage may very wellresult in unsatisfactory processing quality etc.

Contact your local supplier for information about storage requirements forplates and finisher solution. Before making adjustments of the equipmentmake sure that incorrect storage of plates and finisher solution can beexcluded.


5-1Trouble shooting

General

IF a nozzle test shows a drop out of nozzles in either one or several rows, it isimportant first to establish the possible cause of the nozzle loss. It could be inflicted byseveral situations such as:

Problem Possible cause for the error

Random nozzle loss Lack of cleaning or maintenance.

Pump Cap assy malfunction or wear.

Head crash Plate hit the head and damage the surface on

print head.

Nozzles Clogged Head left uncapped for several hours.

iCtP system not used for prolonged period, i.e.

months.

Pump Cap assy malfunction or wear.


5-2Trouble shooting

Before starting troubleshooting

Part 6: Spare parts

Finding a spare part

1. Find the pages covering the section where the part is located.2. Find the specific part and the part’s Pos. No. on the drawing.3. Refer to the list on the opposite page to find the spare part’s number and

specification.

Ordering a spare part

When ordering spare parts please state carefully the spare part number, the partspecification and the number of items wanted and send the order to your spare partsdealer. The cables and their part numbers can be found in the electrical diagramsplaced in the end of this manual.

Original printer spare parts

To obtain the correct order number for original printer spare parts please use the“Imaging Unit” Service manual to find the part number for the part you need, then usethe Cross reference list in this manual to find the corresponding spare part number touse when ordering the part.


6-1Spare parts

1

Spare parts

1 3

Spare parts

Pos. No

Finishing unit

Part No Specification

COVER, BOTTOM, FRONT

COVER, BOTTOM, BACK

TRAY, GUM

COVER, POWER, ENTRY

FILTER, EMC, 1-PHASE, 16A

PLUG, FEMALE, 4-POL.

HEYCO, STRAIN RELIEF, 6.5 MM WIRE

SWITCH, LINE, 16A-FUSED

PIN, GUIDE, TABLE, FEED

GEAR, ¥6, Z16, M2

BUSHING, BEARING

PLATE, AIRFLOW, COOLING ZONE

BEARING, ROLLER, WHITE, 13 KG

CLIPS, R-SHAPE, D2.5X20

GEAR, Z19, M2, D12

GUIDE, PLATE, GEAR

BEARING, ROLLER, SNAP, BLACK

ROLLER, D40X695, EPDM, SHORE 40

ROLLER, EPDM, D40X695, SHORE 18

ROLLER, PUR, D29/30, L680, MODIFIED

STOPPER, SHAFT D10/17.5X7.5

GUM, TRAY, UPPER

COVER, GUM

REFLECTOR, BOTTOM

LED, CONTROL

SELECTOR, PROGRAM

CIRCLIP, D16x1, A2, DIN 471

SENSOR, INK-DRIER/FU

SWITCH, ASSY

BUZZER

10053096

10054423

10053884

26364

10006574

10053883

54381

10012692

16787

10054414

35698

10012622

10012621

10010504

10017962

10017903

10012449

10011013

73241

73262

74038

43600

73942

10005673

10014112

4105

10033993

10018386

10010883

10010945

1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

4

5

6

7

8

9

2

3

FINISHING UNIT

T8552

3

1

2

4

5

67

8

12

1110

9 13

1514

16

4342

41 1817

19

20

21222324

21

20

25

27

24

26

28

29

23

30

3231

33

34

3536

3536

38

39

40

40

37

44

39

40 40

33

25

26 27

2 3

2

T31947

Service Manual - PlateWriter™ 2500/3000/NewsWriter™ 1425 1425 Service Manual - PlateWriter™ 2500/3000/NewsWriter™


6-2Spare parts

1

2

3

4

5

6

7

8

9

108

10

1311 14 15

16

12

TOTAL MACHINE

T8927

17

19

Total machine

Pos. No Part No Specification

1 10070232 TABLE, INPUT

2 10070206 FENDER, RIGHT

3 10071504 LID, TOP

4 10069557 INK-DRIER, COVER, EXIT

5 10070232 TABLE, EXIT

6 10065988 TUBE, EXTENSION, INPUT, FINISHING UNIT

7 87571 ROLLER, WITH HOLDER, COMPLETE

8 10069536 LID, FINISHER

9 10076066 FENDER, LEFT

10 10010948 CONTAINER, 1L

11 1504 NUT, M10

12 0011841 LEG, ADJUSTABLE, M10 x 50

13 10075282 BRACKET, BOTTLE

14 10065977 EXTENSION, EXIT, FINISHING UNIT

15 10060979 TUBE, EXTENSION, SHORT, FINISHING UNIT

16 10078017 BRACKET, RIP, STATION

17 10069523 LEG, LEFT, STAND

18 10070202 LEG, RIGHT, STAND not shown

19 10080880 BOTTLE, 500ML

20

21

22

23

24

25

26

27

28

29

30


6-3Spare parts

Total machine


6-4Spare parts

1

1

2

3

3

4

5

7

6

8

REGISTRATION SYSTEM, PRINT BED AND HEATER

14

1516

171819

18

2021

22

34

24

25

26

27

2829

30

31

32

33

23 9

10

11

12

34

12

13

35

36

37

Registration system, print bed and heater


1 10046143 FAN,127x127x38,5214NH,24VDC,PAPST

2 10069588 HEATING,ELEMENT,750W,L=950

3 1879 SLEEVE 3/8" BLACK TP.VERSAFIT

4 10043571 BRACKET,INK-DRIER

5 10069551 COVER,INK-DRIER,EXIT,36"

6 10071113 IEC APPLIANCE COUPLER,6.3mm,c14

7 10070250 SENSOR,REFLECTIVE,25MM,W. CONNECTOR

8 10069552 PLATE,INNER,INK-DRIER,EXIT,36"

9 10087697 BASE,PRINT,PLANE,SOLID,36"

10 10087698 TOP,PRINT-BED,SOLID,36"

11 15298 SCR M3X10 CR P4

12 10087566 HOLDER,PRINT,PLANE,36'',LH

13 10087368 HOLDER,PRINT,PLANE,36''

14 10069334 GUIDE,REGISTRATION,EXIT,36"

15 10069530 ECCENTRIC, WASHER,ADJUSTMENT

16 10065609 GROMMET,D10XD20,CONIC

17 10061037 BRACKET,SENSOR,REGISTRATION

18 10009707 SENSOR,OPTICAL,(16436)

19 53916 HOLDER,FOR,ROLLER,GUIDE

20 35907 SHAFT,ROLLER,D3,L=33

21 73245 ROLLER,D13/D3,3X25,5

22 87571 ROLLER,W/HOLDER

23 10069332 BRACKET,REGISTRATION,EXIT,36"

24 10061032 PIN,REGISTER,L=18mm

25 10061031 BUSHING,REGISTER

26 10060971 HOLDER, PIN

27 10061032 PIN, REGISTER, L=18MM

28 10060970 LIFTER, REGISTER

29 10061033 BRACKET,REGISTER

30 10057826 CAM,FRONT,REG

6-5Spare parts




6-6Spare parts

1

1

2

3

3

4

5

7

6

8

REGISTRATION SYSTEM, PRINT BED AND HEATER

14

1516

171819

18

2021

22

34

24

25

26

27

2829

30

31

32

33

23 9

10

11

12

34

12

13

35

36

37



31 10057728 MOTOR,24VDC,GEAR

32 10061035 BUSHING,SHAFT,REGISTER

33 10069329 SHAFT,FRONT,REGISTER,36"

34 15455 SCREW,M3X5,CR,P,DIN7985A-Z

35 1558 SCREW,M6X20,HE,SO,CP,DIN916

36 15323 SCREW,M6X16,HE,SO,CH,DIN912

37 10069546 SA,TOOL,ADJUSTMENT,PRINT-BED

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

6-7Spare parts




6-8Spare parts

T8929

DRYER AND CURING

1

1

1

1

1

2

2

2

2

2

3

3

3

3

3

3

3

3

3

5

5

5

5

5

4

4

4

4

4

6

7

8

Dryer and curing


1 10065128 BULB, HALOGEN, 160W, 230V, 2900K

2 10065127 BULB, HALOGEN, 240W, 230V, 2900K

3 10010361 SOCKET, HALOGENLAMP

4 10012598 FUSE, THERMAL, 184°C

5 10014276 TERMINAL, 3-CIR, PORCELAIN

6 10053094 TEMPERATURE, SENSOR, CURING UNIT

7 10019245 GUARD, METAL, FAN, (FG-12), 120 x 120

8 26054 FAN, SUNON

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30


6-9Spare parts

Dryer and curing


6-10Spare parts

9

1

1

2

2

3

3

4

4

5

5

6

67

7

8

SIDE MEMBERS

Side members


1 10085001 SA, FU, FRAME, LEG, PAINT

2 10084999 BRACKET, SNAPLOCK, PAINT

3 15288 SCREW, M5X12, CR, P, DIN7985A-Z

4 10065890 POSITION, PIN, GN 608. 1-8-8

5 15392 SCREW, M5X8, CR, C, FL, DIN965A-Z

6 0011841 LEG, ADJUSTABLE, M10X50

7 1504 NUT, 10, A4, DIN934

8 10084995 CROSSMEMBER, FRAME, FU, PAINTED

9 10001424 SCREW, M6X16, HE, HFC8007, FZG

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

6-11Spare parts

Side members



6-12Spare parts

T8931

FINISHING UNIT

7

2

3

6

8

4

5

1

10

12

13

9

11

16

15

14

20

43

1718

44

5847

4849

504641

52

53

54

4532

29

33

38

36

3635

35

37

34

39

4647 40

4232

30

62

60

58

22

57

27

31

28

26

24

25

2223

24

23

21

5661

5955

60

59

51

Finishing unit


1 10064631 COVER, BOTTOM, FRONT

2 10064653 COVER, BOTTOM, BACK

3 10064335 TRAY, GUM

4 10065870 COVER, POWER ENTRY

5 10053884 FILTER, EMC, 1-PHASE, 16A

6 26364 PLUG, FEMALE, 4-POLE

7 6295 GROMMET, D6/9 x 1.5

8 10053883 SWITCH, LINE, 16A-FUSED

9 54381 PIN, GUIDE, TABLE, FEED

10 10012692 BUZZER

11 16787 SWITCH, ASSEMBLY

12 10054414 SENSOR, FINISHING UNIT

13 35698 CIRCLIP, D16 x 1

14 10012622 SELECTOR, PROGRAM

15 10012027 LED, HOLDER

16 10065134 REFLECTOR, BOTTOM

17 10017962 GEAR, ¥6, Z16, M2

18 10017903 BUSHING, BEARING

19 10012449 PLATE, AIRFLOW, COOLING ZONE

20 10012621 LED, CONTROL

21 73241 CLIP, R-SHAPE, D2.5 x 20

22 73262 GEAR, Z19, M2, D12

23 74038 GUIDE, PLATE, GEAR

24 43600 BEARING, ROLLER, SNAP, BLACK

25 10033456 ROLLER, D40 x 870, EPDM, SHORE 40, BULGED

26 10001918 ROLLER, EPDM, D40 x 870, SHORE 18

27 10064625 ROLLER, PUR, D29, L860, MODIFIED

28 4105 STOPPER, SHAFT D10/17.5 x 7.5

29 10064633 GUM, TRAY, UPPER

30 10064333 COVER, GUM

31 5001 SCREW, ALLEN, 3 x 4

32 10036887 FITTING, ELBOW, M5 x D3


6-13Spare parts

Finishing unit


6-14Spare parts

T8931

FINISHING UNIT

7

2

3

6

8

4

5

1

10

12

13

9

11

16

15

14

20

43

1718

44

5847

4849

504641

52

53

54

4532

29

33

38

36

3635

35

37

34

39

4647 40

4232

30

62

60

58

22

57

27

31

28

26

24

25

2223

24

23

21

5661

5955

60

59

51

Finishing unit


33 10064337 CONVEYOR, ROLLER, DRIVEN

34 10039435 BELT, CONVEYOR, LONG, OPEN

35 10025228 GEAR, Z24, M2

36 1530 SCREW, M4 x 12

37 10064602 BELT, CONVEYOR, WASH-BRUSH

38 10034139 O-RING, D38 x 7, HA1470, EPDM

39 10064646 ROLLER, DRIVEN, FINISHING UNIT, EXIT

40 10064656 CONVEYOR, ROLLER

41 10062939 BRACKET, DRYER

42 10064643 CONVEYOR, ROLLER

43 10034314 BRACKET, SUPPORT, GUM TRAY, LEFT

44 10034313 BRACKET, SUPPORT, GUM TRAY, RIGHT

45 10063512 BEARING, GUM SECTION

46 73012 GEAR, Z20, D10/7.5, M1

47 5000 SCREW, ALLEN, 3 x 6

48 10063593 SHAFT, GEAR, INTERMEDIATE

49 35075 WASHER, NYLON, D16/10.2 x 0.5

50 10066452 GEAR, Z34, D10, M1

51 10030326 BUSHING, D16/19 x 1.6

52 25177 HOSE, SILICONE, D6/10

53 25293 FITTING, VALVE, ADJUSTABLE, D12

54 12353669 Y-FITTING, HOSE, UNION

55 5017 SCREW, M4 x 5

56 10002482 ROLLER, RUBBER, D25, L926

57 10064621 ROLLER, PUR, WASH-BRUSH, COMPLETE

58 15400 SCREW, M3 x 12

59 10065218 SPRING, D5.5 x L20, 18N

60 10065044 BEARING, SLIDE, D12 x 16, L19

61 10063596 GEAR, M2, Z12, W/M4

62 24593 GEAR, Z34, D9.9/35.7 x 7.5, M=1

63


6-15Spare parts

Finishing unit


6-16Spare parts

T8932

ELBOX, COOLING ZONE

1

1

19

22

3

4

5

67

8 7

9

10

11

12

14

15

15

13

12

16

15

17

1716

16

16

18

16

Elbox, cooling zone


1 10064345 BARRIER, AIR, COOLING ZONE

2 6328 GROMMET, D37

3 10064779 SIDELID

4 10017862 TRANSFORMER, CURRENT

5 10056069 PCB, PCU (Note: Without software)

6 10011284 FUSE, 1AT, 5.08MM, VDE

7 26054 FAN, SUNON

8 10053796 FILTER, EMC, 1-PHASE, 2A, FMLB-41

9 10051945 PSU, AC>DC, 230-24, 125W, OPEN, PPS-125-24

10 10060048 SPACER, M3 x 6 + 35

11 10053159 SHIELD, PLASTIC

12 10014349 CASSETTE, PUMP

13 10039880 PUMP, WATER, K2, X18

14 10039879 PUMP, GUM, K1, X20

15 10038867 FITTING, TEE, HOSE, 3 x 3 x 3

16 10065976 HOSE, SILICONE, d3/D5

17 10062934 CHECKVALVE, PP/SILICONE, 1/8" x 1/8"

18 10046142 FITTING, HOSE, D3 x D3

19 10067318 BARRIER, AIR, CURING

20

21

22

23

24

25

26

27

28

29

30


6-17Spare parts

Elbox, cooling zone

Cross reference list

G&J Part No Specification

10083110 PAD, FLUSHING, BOX

10078467 PUMP, CAP, ASSY, WIPER

10078466 DUCT, CR, ASSY ESL, F, ASP

10082671 BOARD, ASSY, MAIN

10088910 FLASHING, BOX

10086786 HARNESS, PANEL

10086787 PANEL, ASSY, AD, ESL, ASP

10086788 SCALE, CR, 36, ASP

10086789 BOARD, ASSY, INK, MARK, B

10086790 BOARD, ASSY, DETECTOR, PW, B

10086791 TIMING, BELT, CR, 36

10086792 MOTOR, ASSY, CR

10086793 MOTOR, ASSY, PF

10086701 HOLDER, ASSY, IC, B, ASP

10081494 PRINTHEAD, IC856V-3, 3600

10086738 PUSH-FIT, FITTING, 3/16" - 3/16"

10083378 PUMP, FLUID, CAPPING, PW3600

10078418 SENSOR, LEVEL, LIQUID WITH CABLE

10088729 SA, CHIP, AR, RIGHT

10088730 SA, CHIP, OT, LEFT

10089210 INK, ABSORB, TRAY, BOTTOM, LAYER

10089609 INK, ABSORB, TRAY, TOP, LAYER


6-18Spare parts

Maintenance kits

Part No Specification

10082610 SERVICE KIT, PERIODIC


6-19Spare parts

Maintenance kits


6-20Spare parts

Appendix A: Electrical diagrams

This chapter includes all electrical diagrams for the PlateWriter™ 3600 Pro.

The diagrams (4 pages) cover:

• Page 1 of 4:Main power distributionMain switch and primary voltage

• Page 2 of 4:Low voltage wiringSensors, switches, LEDs and motors

• Page 3 of 4:Printer planeWiring schematic

• Page 4 of 4:Optional ink dryerWiring schematic


A-1Electrical diagrams

Main power distribution

Main switch and primary voltage



Main power distribution

GND of Lside member

M2

GG

GG

G

X37,3X37,8

Gro

und

bar i

nEl

ectr

onic

s

X27,14X27,13

Cur

ing

Ove

n

2C

N1

31

24 V

Pow

er S

uppl

y U

nit

X17,

1X2

5,1

X26,

1

X16,

2

X23,

3

X6

X106

hot 2

34

83

Max 1A

X102

3

Pow

er C

ontr

ol U

nit,

PCU

X109

64

hot 3

32

45

X108

21

4

hot 1

X101

24

72

43

Max 1A

retu

rn 3

Max 1A

retu

rn 2

X103

11

84

1

X105

X104

Line

filte

r

4

retu

rn 1

6

X15

23

4

3

1

54

78X107

G

26

18

2

3

75

6

1005

5006

10

53

2

Non interrupted

31

7

AC/N

61

5

Max 1A

6

G

12

G

2

21

8

X26,

1

17

Non interrupted

35

X26,

2

X26,

3

1005

5005

84

32

16

75

X35

10066232

2

X27,1

X27,2

X101,1

X101,3

98

43

21

67

510

G Coo

ling

Fan

M2,1

M2,2

X37,6

X37,4

X103,2

X103,4

1

See

pag

e 2

for c

onne

ctio

ns

X104,7

X104,4

X27,5

X105,63

X107,4

X107,7

X27,7

X27,8

X27,10

X27,11

X27,12

X27,6

X105,7

X105,4

X105,2

X106,2

X106,1

X106,3

X106,4

2X4

91

3

X27,9

Rec

epta

cle

for:

Ink

Dry

er -

see

page

4

1006

6099

240W

64

X37

X27

139

1006

6238

1211

85

76

X104,1

X37,3

10066236

10066234

10066231

10066202D

ryer

CN

5:1,

2, 3

: +V

5, 6

, 7: -

V

160W

240W

160W

240W

160W

240W

160W

240W

160W

24 V

dc, 4

.2 A

Fold

bac

k lim

iter

68

7

X14

12

1005

4948

1006

6239

X16,

1

X17,

2

X24,

3

X25,

2

AC/L

X25,

3

X26,

2

X26,

3

8

GN

D o

f Rsi

de m

embe

r

14

22

P1

21P

2

11

Cov

er S

witc

hC

urin

g O

ven

1212

2122

11

Par

t of 1

0060

801

Pow

er L

ine

filte

r

PEP

art o

f 100

6080

1

Par

t of 1

0060

802

Par

t of 1

0060

802

Low

er c

hass

is p

late

Par

t of 1

0012

624

X7

1007

7261

57

3 4

Par

t of X

27L

side

mem

ber

21

43

Cov

er S

witc

hD

ryer

IEC

app

lianc

e co

uple

r23

0 Va

c, 2

W +

PE/

230

Vac,

1 W

+ N

+ P

E

On-

Off

Switc

h w

ith 1

6A c

ircui

t bre

aker

NL

Par

t of X

37R

sid

em

embe

r

1007

7261

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

App

rova

l:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

ADA10

0774

09M

ain

Pow

er D

istri

butio

n

Mai

n S

witc

h an

d P

rimar

y V

olta

ge

Thur

sday

, May

21,

201

5

14JW

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

App

rova

l:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

ADA10

0774

09M

ain

Pow

er D

istri

butio

n

Mai

n S

witc

h an

d P

rimar

y V

olta

ge

Thur

sday

, May

21,

201

5

14JW

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

App

rova

l:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

ADA10

0774

09M

ain

Pow

er D

istri

butio

n

Mai

n S

witc

h an

d P

rimar

y V

olta

ge

Thur

sday

, May

21,

201

5

14JW

F618

4°C

F418

4°C

RV?

S14K460

470

K

2.2 nF

?

E14

E12

F7 1AT

M

M3

100

nF

E19

F718

4°C

Q?

BTA

16RV

?

S14K460

E11

RV?

S14K460

RV?

S14K460

M

M11

S3

E20

2 x

0.64

mH

L1

Q?

BTA

16

?

Q?

BTA

16

Q?

BTA

16

100 nF

?

2 x 4 mH

L2

Q?

BTA

16

100

nF

Q?

BTA

16

4.7

nF

Q?

BTA

16

470 K

RV?

S14K460

RV?

S14K460

Q?

BTA

16

M

M2

RV?

S14K460

Q?

BTA

16

2.2 nF

4.7

nF

Q?

BTA

16

F6 1AT

S2

Q?

BTA

16

Q?

BTA

16

E16

Q?

BTA

16RV

?

S14K460

Q?

BTA

16RV

?

S14K460

E18

RV?

S14K460

F318

4°C

?

RV?

S14K460M

M9

?

E17

Q?

BTA

16

E15

RV?

S14K460

Q1

RV?

S14K460

RV?

S14K460

F8 1AT

RV?

S14K460

M

M4

E13

RV?

S14K460

?

Q?

BTA

16

F518

4°C

Low voltage wiring

Sensors, switches, LEDs and motors



Low voltage wiring

Anti-

stic

kso

leno

id ri

ght

Red

21

+

X11,4

-

X11,3

X9

Black

Anti-

stic

kso

leno

id le

ft

Red

21

+

X11,2

-

X11,1

X8

Black

Belt

Mot

or

Plat

e be

fore

oven21

Enco

der o

r Hal

lge

nera

tor

(Opt

iona

l)

X8,1

Yellow

Blue

Black

Red

++

Mat

eria

l sen

sor (

refle

ctiv

e)

Red

Black

Rea

dout

: 1 2

4 8

1

2 3 4 5 6 7

Buzz

er

B1

Con

nect

or fo

r opt

ions

: Pla

te D

ryer

- se

e pa

ge 3

Ink

Dry

er -

see

page

4

Brown

Brown+

X48

2

H2

Sta

te In

dica

tor

31

8X4

33

26

57

4

2

X47 1

4

X45

3

X44 1

2

Black

Red

X114,11

X114,12

X11,14

X204,9

X114,1

X113,2

X113,1

X11,8

X11,7

X48,2

X45,1

X43,7

X43,8

X46,4

X9,9

X118,2

X118,1

X114,3

X114,4

X118,9

41

2

12

48 Pr

ogra

m S

elec

tor

C

X46

13

42

X114,10

X114,9

X114,7

X114,5

Tem

p Se

nsor

Ove

n

R1

4

X41

32

1 Green (+)

WhiteX118,4

X118,3

Thermocouplertype K

X20,2X114,2

note

:N

iCrN

i (K)

ther

moc

oupl

er 4

0μV/

°C10

0°C

= 4

.096

mV

200°

C =

8.1

36m

V

9

X113,3

1

X113,4

X45,2

Cur

rent

pic

k-up

trans

form

erG

um p

ump

Red

21

+

X11,5

-

X11,6

X20

Black

X204,7

Wat

er p

ump

Red

21

+

X4,4

-

X4,1

X18

Black

CN

5, 8

CN

5, 3

+ 24

Vdc

5

Dua

l Mot

or C

ontro

ller

63

CN

5, 1

42

CN

5, 6

X5

1

X1 4 1 5 2Part

of P

ower

Con

trol

Uni

t, PC

U

36

0 V

CN

5, 2

CN

5, 7

+ 24

Vdc

(DC

out

put s

uppl

y)

+ 3.

3 Vd

c(m

icro

cont

rolle

r circ

uitry

)

+

DC

DC

signal

+

signal

+

24 V

dc fr

omC

N 5

on

PS

U 1

+ 5

Vdc

+

X4

24

15

36

43

87

12

56

1211

910

X114Signal

Signal

Signal

Signal

Signal

Signal

56

8

X11

1211

1014

139

71

24

3

X119

Sign

al A

/V

4 13 2

X118

+24V

dc

Pul

sed

outp

ut

X45,3

X45,4

X43,1

X43,9

3

X113

24

1

Blue

X20,1

X44,2

X44,1

X18,2

X18,1

X46,1

X47,1

X47,2

1 2

X910

93 A

cha

nnel

0.75

A c

hann

els

X43,3

X46,3

X46,2

X9,1

Yellow

5

X36

43

10055004

10054788

9

1006

5843

X10

72

15

64

312

1114

138

109

Sin

e w

ave

+

X13

72

15

63

1211

1413

810

921

1615

1920

1817

2325

24

X4,6

X10,7

X114,15

X114,13

X11,10

X10,1

X,36,9

X4,3

X11,9

X10,4

X204,5

X204,3

X10,3

X10,6

X204,1

X10,14

X10,11

X10,8

X36,10

X10,2

X10,10

X10,12

X13,11

X13,5

X13,18

X13,12

X13,7

X13,13

X13,25

X13,21

X13,8

X13,20

X13,24

X13,23

X13,1

X13,14

1615

1314

109

X13,3

X13,16

X13,15

X13,19

X13,6

X23,5

X23,3

X21,5

X21,3

X21,1

X22,1

X23,1

X21,4

X21,2

X21,7

X24,3

X24,1

X21,8

X21,9

X24,2

X21,6

X23,9

X23,8

X23,4

X23,2

X22,2

X23,6

X23,7

98

31

56

24

7

X21

101

2

X22

109

83

15

62

47

X23

31

24

X24

X13,11

X13,16

X13,2

X13,14

X13,1

X13,15

X13,3

X13,13

X13,12

X13,23

X13,21

X13,7

X13,19

X13,6

X13,20

X13,8

X13,25

X13,24

X13,5

X13,18

X13,9

X13,10

X13,17

2

12

12

Reg

istra

tion

pins

Sens

or p

ins

enga

ge

Reg

istra

tion

indi

cato

rG

reen

:OK

Red

: Not

OK

1006

6225

10066224

10066224

1005

8401

Sym

bolic

topv

iew

(wire

ent

ry) o

f con

nect

or X

114,

X11

8, X

204

and

X205

sho

win

g pi

n 1&

2

PIN

#1

PIN

#2

10

X41

,1

X41

,2

Ntc

inpu

t tab

le

Sign

al

2mA

DC

X43

,2

X43

,4

X43

,5

X43

,6

Pin

lift

mot

orSe

nsor

pin

sho

me

Plat

e pr

esen

tse

nsor

Pin

lift

mot

or

Side

regi

stra

tion

mod

ule

(Opt

iona

l)Fr

ont r

egis

tratio

n m

odul

e (O

ptio

nal)

X118,10

Sign

al

K-re

f

43

21

VioletRed

Orange

Black

43

21

VioletRed

Orange

Black

43

21

VioletRed

Orange

Black

Sens

orpi

ns h

ome

43

21

VioletRed

Orange

Black

Sens

or p

ins

enga

geR

egis

tratio

npi

ns

Signal

Signal

1 42 3

X112

US

B,1

US

B,2

US

B,3

US

B,4

10059254

Sign

al to

prin

ter

X36,

3

X50,

14

X50,

15

3

Inpu

t fro

m s

enso

ron

prin

thea

d

85

X36,

310

X205

2

1005

8401

X8,2

X9,2

2

X205,3+10

X50,2+8

X??.1

X??,9

89

23

45

67

1

X50

1415

1011

1213

X204,10

X36,2

X36,1

X36,2

X11,12

X11,13

X205,8

X205,5

Con

nect

or fo

r Flu

id In

Cap

sys

tem

and

Opt

iona

l Prin

t hea

d pr

otec

tion

syst

em

1

103 71 5

X204 9

X50,

10

X13

,10

X13

,17

X13

,9

X48

,1

X48

,3

USB

B1

34

2

X112,4

X112,3

X112,2

X112,1

X50,3

X50,9

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

App

rova

l:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

ADA10

0774

09Lo

w V

olta

ge W

iring

Sen

sors

, sw

itche

s, le

ds a

nd m

otor

s2

4JW

Thur

sday

, May

21,

201

5

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

App

rova

l:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

ADA10

0774

09Lo

w V

olta

ge W

iring

Sen

sors

, sw

itche

s, le

ds a

nd m

otor

s2

4JW

Thur

sday

, May

21,

201

5

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

App

rova

l:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

ADA10

0774

09Lo

w V

olta

ge W

iring

Sen

sors

, sw

itche

s, le

ds a

nd m

otor

s2

4JW

Thur

sday

, May

21,

201

5

M

K2S6

BC

D

F24

0.6

AT

NC

+

-

BTN7930

F18

1.5A

T

F28

4AT

R2

82R

U37

LM78

L05

IN8

OU

T1

GND3

1

270R

47R

K4

+

-

+

-

MM

8

K3

BTN7930

270R

R7

82R

S5

NC

134 5 6

BTN7930

+

-

M

M1

3

H1

BTN7930

T2

Q41

1.

23

F27

2.5

AT

270R

1 3456

M

K1

1

4k7

F? 1.5A

T

BTN7930

+

-

270R

BTN7930

47R

+

-

+

-

3

MM

7

R3

82R

R4

82R

Printer plane

Wiring schematic



Printer plane

1006

7530

1006

7865

1006

9388

1

Red

Blac

k

Ora

nge

Blac

kO

rang

eR

edW

ires

conn

ecte

d to

prin

ter c

ontro

l

Lid

switc

h on

prin

ter

Low

Vol

tage

conn

ecto

r to

Fini

sher

Ele

ctro

nics

(pag

e2)

X100

Prin

t hea

d se

nsor

B1

+

41

2

Liqu

id le

vel

X45

3

X50,1

X50,3

X8,

1

X50,2

8 92 3 4 5 6 71X50

14 1510 11 12 13

-

Liqu

id s

olen

oid

21

X50,1

X50,9

X8

Opt

iona

l

1007

7288

Com

NC

NO

2 3 4 5 6

7 8 9 10 11 12

X8,

2

X45

,2

X45

,1

X10

0,1

X10

0,2

X10

0,3

X45

,3

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

Appr

oval

:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

AD

A10

0774

09

Wiri

ng s

chem

atic

FIC

& P

rint h

ead

syst

em

34

MLS

Thur

sday

, May

21,

201

5

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

Appr

oval

:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

AD

A10

0774

09

Wiri

ng s

chem

atic

FIC

& P

rint h

ead

syst

em

34

MLS

Thur

sday

, May

21,

201

5

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

Appr

oval

:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

AD

A10

0774

09

Wiri

ng s

chem

atic

FIC

& P

rint h

ead

syst

em

34

MLS

Thur

sday

, May

21,

201

5

3 4

1

2

K5

1

Ink dryer

Wiring schematic



Ink dryer

1007

7252

B2

Red

21

4

X1

3

12

X43

Air T

emp

Air F

an,In

k-dr

yer

Air F

an,In

k-dr

yer

Con

nect

or o

n Fi

nish

er U

nit (

page

2)

12

note

:P

t 100

0:0°

C =

100

0 oh

m25

°C =

109

7 oh

m10

0°C

= 1

385

ohm

12

Sup

ply

from

X49

in

Fini

sher

Uni

t (pa

ge 1

)

X3,1

X4,1

750W

21 PE

BTC

BTC

: Bui

lt in

ther

mal

cut

-off

with

sel

f hol

d fe

atur

e

9851

5

983 5 62 4 7

X2

1

8 92 3 4 5 6 71

1007

1118

2 14

X?

3

1 2

Air F

anPr

int-H

ead

1007

1129

1007

7794

Black

White

Green

Bla

nk a

rea

on p

rinth

ead

Ink

drye

r enc

losu

re

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

Appr

oval

:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

AD

A10

0774

09

Wiri

ng s

chem

atic

Ink

Dry

er

44

JW

Thur

sday

, May

21,

201

5

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

Appr

oval

:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

AD

A10

0774

09

Wiri

ng s

chem

atic

Ink

Dry

er

44

JW

Thur

sday

, May

21,

201

5

ELEC

TRO

NIC

AN

D M

ECH

AN

ICA

L EN

GIN

EER

ING

This

dra

win

g be

long

s to

Glu

nz &

Jen

sen

A/S

unau

thor

ized

per

son

with

out o

ur s

peci

fic p

erm

issi

on.

Num

ber:

Rev.:

Page

:O

f:

Dat

e:Title:

Function:

Con

stru

ctor

:Doc. No.:

Appr

oval

:an

d m

ust n

ot b

e us

ed o

r han

ded

over

to a

ny

OrC

AD

A10

0774

09

Wiri

ng s

chem

atic

Ink

Dry

er

44

JW

Thur

sday

, May

21,

201

5

130

°C

150R

M

M5

M M?

E5

R3

Pt 1

000

MM

6

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