Dolev 800/800V/800V² TIC -  Installation
Punch/On-Line Conveyor
Installation

Air Tube, Slug, Wiring and Speed Adjustments

Preliminary
Air Tube Routing
Slug System Routing
Electrical Wiring

Preliminary

Refer to:    Waste Slug Tube Routing

1. Deactivate the air pressure supply to the Imagesetter.

Air Tube Routing

2. Perform final routing of the black air tubes for all punch assemblies. Use the following guidelines:

1. The UNIT IN/OUT tubes are stationary. Route these tubes shortly, without bending and in alignment with their natural curvature.
   
2. The punch rod IN/OUT and slug air tubes move during the punch sequence. Route them together when the punch assemblies are at their OUT position. Carefully check for freedom of movement by moving the punch units manually from their OUT to IN positions and back again. Ensure that these units are not interfering with any of the photo-interrupters.
   
3. Air tubes should be free of stretching.
   
4. Air tubes should not interfere with any moving parts of the Imagesetter.
   
5. Do not tie any air tube. Simply cut them to their final length and poke them into place.

3. Activate the air pressure to Imagesetter.
   
   
4. Restart the Imagesetter and ensure proper operation of all punch assemblies.
   
   
5. Set up the Imagesetter as follows:

1. Air pressure level is 1 atm (14 psi).
   
2. Top cover, rear upper cover and right door are removed.
   
3. All but one punch assembly are electrically disconnected.
   
4. All punch mouths are removed from the punch assemblies.
   
5. All punch assemblies are at their OUT position.
   
6. No film is loaded.
   
7. Optics carriage is at its END position.
   
8. The Imagesetter is completely cleaned of slugs, short black tubes, cable ties, lost fasteners, tools, etc.

Slug System Routing

6. Install the black 38 mm waste slug collection tube.

1. Locate and remove the black tape attached to the internal lower right light cover (under the loading motor on the standard controller side of the Imagesetter). This tape covers a 38 mm hole in the cover, which is used to support the end of the collection tube.
   
2. Install the end cap of the 38 mm black hose into the uncovered hole. Twist the tube 2-3 turns so that it fits inside the cavity next to the standard controller. The open end of the collection tube should be oriented upward, toward the punch assemblies.
   
   Note: On some machines, you will need to attach the special adaptor plate, supplied with the pneumatic system kit, to the internal light cover.

7. On a clean space, organize all punch assembly mouths, along with their screws, green "garden hose" air tubes, L-shaped black fittings, T-shaped black fittings, and cable ties. Also have available the tube cutter (supplied with the Pneumatic Control System).
   
   
8. Insert completely each of the punch mouths into a separate 120 mm long green air tube.
   
   
9. Insert partially (up to 10 mm deep) each of the L-shaped black fittings into the other end of the 120 mm green air tubes.
   
   
10. Install the punch mouths on the various punch assemblies.
    
    
11. Route the green air tubes using from one to three circular branches around the drum axis. The following figure provides a typical tube routing example. Since there are numerous punch system configurations, there is no specific, straightforward model for routing slug system tubing. It is acceptable to route identical punch systems in different ways. However, the follow rules and guidelines exist for routing:

1. Arrange the green air tubes so that three (3) tubes will arrive to the single black 38 mm waste slug collection tube.
   
2. Use the natural curvature of the green tubing. Don't attempt to force the tubing against its nature.
   
3. Ensure that the air tubing is fresh, i.e., soft and flexible. Otherwise, an excessive force will be applied to the linear bearing, reducing repeatability and registration quality.
   
4. Ensure likewise that the air tube routing is such that it applies the minimum load on linear bearings.
   
5. Avoid applying excess force on the linear bearing while insert the air tubes.
   The air tubing should be inserted a minimum of 20 mm over the black plastic fittings.
   
6. Do not use grease when inserting the fittings into the air tubes.
   
7. The air tubes should not come into contact with any stationary part during UNIT IN/OUT operation.
   
8. Use the absolute minimum of union T- or L-shaped fittings.
   
   Warning: Do not perform a UNIT IN when the optics carriage is at its end position. The punch assemblies can collide with the carriage. Instead, always move the punch units manually.
   
   Waste Slug Tube Routing
   
   
   
   Plan ahead before performing air tube routing. It is difficult to disconnect the hoses from the various fittings.

12. Route the free ends of the green air tubes into the single black 38 mm slug collection tube. A maximum of three (3) green tubes will fit inside this tube. The green air tubing should extend 100 to 150 mm into the fat collection tube.
    
    
13. Reset the air pressure to 6.5 atm (92 psi) and perform several loading and film punching sequences. Check for smooth operation of the punch system. Ensure also that all film slugs are ejected well into the collection cavity.

Electrical Wiring

14. Connect and route all unconnected electrical wires for each punch:

1. the PUNCH ROD IN photo sensor connector
   
   
2. the UNIT IN/OUT photo sensor connectors

Tie together the three moving black air tubes with the moving wires of each punch unit. Do the same to the stationary black air tubes and the stationary branch of wires. Cable ties are supplied with the punch system kit.

15. Adjust the air flow controllers for each of the punch assemblies:

1. Loosen the securing nut for each valve on the assembly.
   
   
2. Rotate the air flow adjusting screw for each valve.
   Clockwise rotation reduces the air flow.
   Counter-clockwise rotation increases the air flow.
   
   
3. Tighten the securing nut for the adjusted valve.

16. Air flow is adjusted ideally when the following conditions are met:

1. All punch UNITS arrive together to their IN/OUT positions within 0.5 seconds.
   
   
2. All punch RODS arrive together to their IN/OUT positions within 0.3 seconds.
   
   
3. UNIT IN/OUT stroke is from 0.8 to 1.3 seconds long.
   
   
4. ROD IN/OUT stroke is from 0.4 to 0.6 seconds long.
   
   

It is recommended that you use the Diagnostics module to determine operating cycle times.

Each operation is displayed, including its execution times. An experienced engineer can adjust the system manually in a few moments.

Note that flow controllers control only the air flow exhausted from their cylinder.