Punch System

• Order Form
• Customized Head Punch - pdf
• Customized Side Punch - pdf
• Catalog Numbers
• Side Punches (memo)
• Bar Punches - pdf (24 Jun 03)
• Bar Punch Offset in PS/M 7.x - pdf (31 Oct 02)
• See FCO 21421 New Vacuum Tunnel Adaptor (memo)
• Bar Punch Calibration (memo)
• Installation
• Overview
• Mechanical Installation
• Electronic Installation
• Calibration Procedure

Overview

Important: Only a trained specialist should perform these installations.

This document describes the installation and calibration of the punch system.

The installation includes two stages :

• Mechanical installation
• Electronic installation and Setup

The calibration is performed along the width and height axis referred to the punch center holes on each axis.

Mechanical Installation

Punch Assembly

• Kit Side Punch - Mechanical Installation (memo)

1. Make sure that the punch kit contains all the needed parts:

• Bar punch according to the customer order
• Punch cutouts collector tray
• Bow for bar punch

2. Disassemble the Bow

• Move the carriage to E.P (End Position) and disassemble the Bow by removing the 4 screws that hold it (you will use these screws later to assemble the new bow).
• Move the carriage back in order to release the Bow.

In VER. 5.10 there is a bug that doesn’t allow you to move the carriage to the EP unless there is a film in the drum.

3. Move the carriage back to H.P. ( Home Position ).
4. Power off the Imagesetter.
5. Remove the Bar Punch Plug.

• The plug is attached to the drum by 3 supports.
• Under the 3 supports there might be some spacers.
• Verify that they will not fall.
• Put the Plug with the spacers, screws ‘old’ bow and inside the plotter. ?

6. Remove the film in encoder tear-up clamp.
   Install the Slider (the slider is the shiny metal that the slugs fall on and slip into the slugs basket).
7. Insert the Bar Punch

• Insert the Bar Punch from the right side of the Imagesetter (The EP Side ), by putting it first on the right punch support and slipping it gently into the punch hole in the drum.

It is important not to put any pressure on the drum during this operation.

• Rest the punch on the two Bar punch supports (you may need to move the carriage manually a little bit to the right in order to enable the punch to get into the hole).
• Attach the Bar punch to the supports using 3 10-32 screws (two regular on the right side of the punch and one with shoulders on the left side).
• Make sure that the punch is attached (but not fully tightened) to the support on both surfaces.

8. Check the Punch Position

• Make sure that the punch will not touch the drum. ( Move a piece of film between the punch and the drum in order to check the space between the punch and the drum. Use small pieces of film to change the punch position if necessary.

In order to check the lower side you have to slip a piece of film on the slider into the drum).

• Check with a piece of film the two steps described in fig 1 (A & B below). You can do it by entering the film from the drum side and following the steps. Step ‘B’ is not critical since the film does not usually not reaching this point.
• Check that the piece of film is moving smoothly from the loading cassette side to the drum (regular film direction).
• Check film loading and make sure that the film does not collide with the punch. Manually advance full width of the film.

Figure 1

9. Connect the electric wires.
   Connect the punch motor plug on the right side.
10. Assemble the Punch position flag and the detector.

• Assemble the flag using 4-40 screw.
• Assemble the detector on the left side of the punch.
• Connect the detector wiring (open the cord and find the cable with ‘P- board’ label on it).

M. Board assembling

11. Assemble the punch M - Board

• The punch M-Board is assembled on a special plate that attached to the left plunge (like in Fig 2).
• If a side punch system is installed the M-Board is attached to the punch vacuum pump holder.

If a bar punch is installed remove the cable on the M. Board.

12. Connect the cables between the board and the punch like in Fig. 3.
    Install the slugs basket from the drawer side.

Figure 3

13. Start up the Imagesetter.
14. Run the punch through the plotter utilities.

• Service util / Machine / Punches / Set active, set 0 ‘YES’ and press ‘Done’
• Service util / Machine / Punches / Run

15. Install back the Bow.
16. Setup the punch in the utility (Bar punch address is 0).
17. Continue with the electronic setup (Punch system, Punch name, Pivot and offsets).

Electronic Installation

• FCO 21716 Punch S-II Board (memo)(memo)
• FCO 21563 Punch Master II Board (memo) (memo)

1. After the mechanical installation set the SIDE PUNCH's addresses with the DIP - Switch located on the SIDE PUNCH PWB according to the following table :

2. Connect the wiring according to the wiring diagram.

Click to see the full size

3. Wiring Installation of Head Punch (Bar Punch)

(This List does not refer to Punch Master 2).

The machine has two kinds of wiring, molex6-pin or molex4-pin. The wiring kit contains two kinds of adapters to connect the bar punch slave board - please refer to the wiring description above.

The slave board cat. # is 503A38329 .

1. MOLEX6

Click to see the full size

2. MOLEX4

Click to see the full size

* choke should be connected near the motor.

Calibration Procedure

1. Load new film into the drum and perform attach.
2. From the SERVICE UTILITIES activate all the punches available.
3. ADVANCE 600 and then CUT and COLLECT the film.
4. When installing a SIDE PUNCH system check that the distances between the centers of punch holes are according to the customer's specification.
5. Adjust the side punch's location and repeat steps 2 * 4 until the desired distance is achieved.
6. Select NEW FILE , CT
7. Create a new file : B
   UNI80
   H*W = Full Format according to the following table :

8. Expose the above file with the PUNCH YES option at the expose dialog .
9. If the exposed file's dimension are corrupted measure and write down the missing HEIGHT and WIDTH .
10. Enter PLOTTER SETTINGS / REMOTE MODE / SETUP / SERVICE / PLOTTER SETTINGS
    Change EXPOSE HEIGHT and EXPOSE WIDTH according to the missing dimensions.
11. Repeat step 8 and you should get the right dimensions if not repeat steps 8, 9, 10 till you get the complete file .
12. Enter PLOTTER SETTINGS / REMOTE MODE / SETUP / SERVICE / PUNCH SETTINGS and define the PUNCH SYSTEMS ordered.
    
    SYSTEM NAME : Stoesser, Bacher or other
    PUNCH POSITION : L,R,H,T - select according to Left or Right Side Punch, Head or Tail Punch .
    PIVOT H/W : according to the customer's specification , one PIVOT per PUNCH SYSTEMMin. Film Feed : 559 mm - do not change this parameter
    SUBSET INCLUDES : enter the punch units which are included in the specified PUNCH SYSTEM

Attention: Head punch address is always zero.

13. Perform GET PARAMS FROM PLOTTER .
14. Return to standby mode .
15. Create the calibration file :
16. Select : JOB - Auto , PAGE - Plot
17. Select NEW FILE , LW
18. In the NEW FILE DEFINITION screen enter following parameters:
    File : " CROSS "
    Size : 100 , 100
    Resolution : 80 , 80
    Background : " B "
    Background color : 0 , 0 , 0 , 0
19. Select F1 ( continue )
20. Select " LW Modify " , " New Entry " , F2 (Modify / Create)
21. Select " WINDOW "
22. Toggle the shape to LINE
23. Select F2 ( create / assign )
24. Select
    " LINE WIDTH " = 0.05 mm
    " ENDS " = round
    Point #1 = 50 , 0
    Point #2 = 50 , 100
25. Select F1 (enter shape)
26. Select F2 (create / assign)
27. Select
    " LINE WIDTH " = 0.05 mm
    " ENDS " = round
    Point #1 = 0 , 50
    Point #2 = 100 , 50
28. Select F1 ( enter shape )
29. Select F1 (main menu )
30. Select F1 ( save & exit )
31. Wait until file is created
32. Expose the file CROSS with align to punch format 1 .

Set the punch format the offsets to :

Head Punch - ML - W=30 H=0
Side Punch - TC - W=0 H=30

33. After exposing and developing , measure the distance between the file's reference point and the pivot as shown in figure 1 and figure 2 .

If the distance is bigger / smaller then the Offset From Pivot reduce / enlarge the pivot HEIGHT and / or WIDTH accordingly.

Punch System Option – Installation (1)

In the above figure the difference between the desired and actual measurement is +2 mm, therefore the PIVOT HEIGHT / WIDTH should be changed by -2 mm .

Punch System Option – Installation (2)

In the above figure the difference between the desired and actual measurement is -2 mm in the HEIGHT , therefore the PIVOT HEIGHT should be changed by +2 mm .

In the above figure the difference between the desired and actual measurement is +2 mm in the WIDTH , therefore the PIVOT WIDTH should be changed by -2 mm .

Remark: Change the PIVOT HEIGHT / WIDTH in the punch settings utilities. Don't forget to GET PLOTTER PARAMETERS

34. Repeat the above two steps until the desired distance is achieved .
35. Expose the UNI80 file you created with align to punch to check for possible laser reflections . There should be no reflections. f there are, check your self again with the alignment .
36. The following drawing is for alignment orientation only.

Calibration Procedure - Alignment
Orientation (only)
Click to see the full size

37. The following drawing shows how the different parameters influence the image position .