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

Punch Assemblies Installation

Overview
Punch Assembly Position Calculation
Punch Assembly Installation
Position Adjustments
Air Hose Installation
Electrical Harness Installation
Trial Punch Sequence
Trial Inspection

Overview

Refer to figures:

                Dolev 800 Punch Ruler
                Punch Assembly Parts
                Installing the Slide and Ruler Gauges
                Punch Adjustment Gauge Position
                Punch Adjustment Gauge Detail
                Punch-to-Film Radial Distance
                Assembly Air Tube Connections

This is the main part of the punch installation. The complexity and duration of this part depends mostly on the following aspects:

1. The number of punch assemblies being installed.
   
2. The distance between punch assemblies on the flange.
   
3. The required accuracy of the punch hole distances.

Hint: Preparing materials at the CreoScitex office will save 1 to 2 hours of work in the field. Refer to Section , Off-Site Preparation. Additionally, Punch Unit position calculations (Steps 1 and 2) may also be performed off-site, further reducing time in the field.

Punch Assembly Position Calculation

1. Using the Dolev 800P punch ruler (Cat. No. 737B8F280), prepare an accurate schema for each punch assembly location on the right flange.
   
   Refer to The punch ruler consists of:
           Millimeters/inch scales
           6º index ("+" markings)
           3º index (" º " markings)
           0.5º index (smallest hatch markings on the inner ruler circumference)
   
   The "+" markings correspond to locations of the 1/4-inch screw tappings on the right drum flange, used to secure the punch assemblies.

1. Prepare the ruler by clipping off the punch assembly outlines from either side of the drawing. These outlines are used to simulate placement of the punch assemblies on the flange. Note that these outlines represent either
   
   Right or Big punches. To simulate a Left punch, simply flip the Right outline over and use its backside.
   
   
2. Referring to the exact specifications in the customer-approved layout, position the appropriate punch sub-type (Right, Left or Big) in its specified location on the ruler.

1. The lower endpoint of the Punch Rod Axis indicator line (the end inside the small circle) should be trapped to the center of the cross hair circle inside at the ruler's center.
2. The upper endpoint of the Punch Rod Axis indicator line is used to locate the punch at its exact location on the circular millimeters/inch ruler. Note that the ruler's origin falls at the punch minimum line marking, and not at the film edge.

3. After positioning the punch assembly on the punch ruler, examine the schema and count the number of 0.5 divisions between the Punch Rod Axis and the nearest 3 index mark. Write this number next at the current punch assembly location on the schema. It will be used during installation.

2. From your laptop computer, run the RULER.EXE application.

1. At the Enter Distance... prompt, type in the punch hole distance from the film edge, reduced by 55 mm.
   
   
2. Enter the current punch assembly sub-type at the Right/Left prompt; type R for a Right or Big sub-type, and L for a Left sub-type.
   
   
3. Write the RULER application output (a number between 0.0 and 1.7 mm) on the schema.
   
   
4. Repeat the RULER calculation for each of the punch assemblies.

Punch Assembly Installation

3. Turn on the Imagesetter and load 1180 mm of medium or large film. The film will remain in place throughout the Assembly installation.
   
   Note:
   1. The order of punch assembly installation impacts significantly on the visibility for Step f, below. A counter-clockwise order, starting from the last punch, is usually ideal.
   2. Pay particular attention to the adjustments performed in Steps g-j. Later corrections to punch assembly placement are tedious.
   3. You will need a strong light to perform the punch unit radial distance adjustment, Step f, below.
   4. Always move the punch assembly slowly to prevent a collision at the UNIT IN position. If a hard collision occurs, damage to the hardened mounting surfaces may result.

Caution: Do not open by mistake any of the eleven 1/4-inch screws which are used to attach the right flange to the Imagesetter drum (Refer to ) 2929888024002057.

1. Referring to the schema you have prepared, identify the two (2) 1/4-inch screw tappings on the right flange of the Imagesetter that will be used to secure each of the punch assemblies. Use the two outermost tappings.
2. Install the punch assembly by its base bracket, using two (2) 2-1/4-inch x 1.25-inch screws, with lock washers and washers. Tighten the screws only partially, to allow manual adjustment of the assembly to its final position.
   Position the punch assembly exactly as seen on the schema, relative to its two 2-1/4-inch screws. This will make later adjustments easier.
   For purposes of rough placement, the arced surfaces of the drum and the punch assembly base should coincide.
3. Install the two (2) punch assembly adjustment gauges: the slide (Cat. No. 282B36308) and the ruler (Cat. No. 282B36307). Refer to
   
   Installing the Slide and Rule Gauges
   
   
   
   Note the position of the semi-circular guide hole on the slide gauge. For Right punch types, the guide hole should be on the right; for Left punch types the guide hole should be on the left.
   When placing the ruler gauge on the 2-1/4-inch screw heads, hold it firmly for an accurate reading.

Position Adjustments

1. The left edge of the slide gauge corresponds to the Punch Rod Axis depicted on your schema.
   
   
2. The small holes on the ruler gauge correspond to the 3º index marks on your schema. The ruler index marks represent 0.5º increments.

4. Ruler and slide gauge positions when making punch adjustments are depicted in Rotate the punch assembly (and with it the slide gauge) away from the 3º ruler gauge reference by the same number of 0.5º index divisions as calculated in the prepared schema (Step 1c). Be sure to refer to the same 3º index mark as shown in the schema.
   
   Punch Adjustment Gauge Position
   
   
   
   Punch Adjustment Gauge Detail
   
   
   
   
5. Rotate the punch assembly until the slide gauge line number (the output obtained from the RULER application) coincides with some line on the ruler gauge. If Step d was done correctly, the required rotation will be less than two (2) ruler gauge 0.5º divisions.
   
   
6. Set the punch rod to the OUT position. Moving the assembly back and forth manually, adjust the punch radial distance to effect a smooth interface between the punch cutting blade and the film edge. On contact, the cutting surface should "lick" the film, without bending it. Refer to
   
   Punch-to-Film Radial Distance
   
   
   
   Hint: Direct a bright light into the drum from the opposite end of the Imagesetter to make inspection of the punch-to-film easier.
   It may happen that the punch jaw collides with the film edge at the UNIT IN position. In such a case, change roughly the unit IN position by rotating the adjusting screw clockwise. (Refer to ) Remember to retighten the securing nut after doing so.
   
   
7. Adjust the punch assembly angular orientation to assure that the punch rod axis is directed towards the drum center. To achieve the best angle, simply verify that there is a uniform gap between arcs of the slide gauge and the ruler gauge.
   
   
8. Repeat the previous four steps until all the punch assembly positioning requirements are met. Lock down the two (2) 2-1/4-inch screws of the punch assembly. Check punch assembly positioning again after final locking.
   
   Note: Do not hesitate to tighten the two 2-1/4-inch x 1.25-inch screws to the end.
   
   
9. Repeat Steps d-k for the remaining punch assemblies.

Air Hose Installation

4. Disconnect the air pressure.
   
   
5. Examine the air pressure manifold (attached to the main frame). It contains five (5) blue 6 mm air tubes routed together. At 180 mm intervals, you will find five (5) "T" junctions, blocked with five (5) plugs. Choose the junctions nearest to each of the punch assemblies and unplug its five plugs. A total of five times the number of punch assemblies should be unplugged.
   Manifold air tubes are labeled in two places:
           Near the metal junction group
           Near the operating panel
   
   
6. Connect each punch assembly to its junction with the five (5) black air tubes supplied for each punch assembly, as depicted in When inserting the air tubes to the punch unit, hold it firmly to minimize loads on the linear bearing. Make sure the black air tubes do not interfere with any moving part on the Imagesetter. Manually move the optics carriage to its end position to ensure it does not collide with any air hoses.
   
   Note: The UNIT IN air flow controller rotational orientation is important. After attaching the air tube, rotate the controller toward the assembly adjusting screw (upper orientation) to prevent any collisions with moving parts during the punch sequence.
   
   Assembly Air Tube Connections
   
   
   
7. Connect the opposite ends of the five black hoses to the appropriate air tube on the chosen "T" junction. Each blue air tube is labelled by function.
   
   Air tube functionality is the same at upper and lower horizontal branches, i.e., the upper tube of the upper branch is connected to the upper tube of the lower branch, etc.
   
   Note that final air tube routing, including cutting of the tubes to their optimal length, will be done later.

Electrical Harness Installation

8. Open the punch system electrical harness assembly located near the blue air tubes. It contains ten (10) harnesses, each ending with two (2) Molex connectors. Each harness has a different length and is labeled by punch assembly number. (Punch 1, Punch 2, etc.)
   
   Determine which punch assembly has the easiest access. Choose the harness which connects to this unit, and connect the harness. Leave all other harnesses unconnected.
   
   
9. Activate the air pressure. Be sure that the pressure regulator it is set to 6.5 atm (92 psi). Disconnect the air pressure immediately if you should hear any loud air leakage. Such leakage may occur if you have made the wrong tubing connections.

Trial Punch Sequence

10. Carefully inspect the punch assemblies for the following conditions:

• All units should be at the OUT position.
• All punch rods should be at the OUT position.
• No air leakage not even a small leakage should be occurring.
• No tube or wire should be stressed, stretched or warped.

If air leakage should occur, isolate the source. When tightening air fittings, remember to hold the assembly firmly, to minimize loads on the linear bearing.

11. Unload the film from the Imagesetter.
    
    
12. Set the following NVM parameters:
    
    

    PARAMETER	TABLE OPTION	OLD VALUE	NEW
    Plotter Type	Factory Tables > Plotter Setting	DOLEV800C	DOLEV800PC
    Punch Mode	Factory Tables > Plotter Description	0	1
    Punch Offset	Factory Tables > Plotter Description		0

13. Check again to ensure that the air pressure is set to 6.5 atm (92 psi) and that no obstructions lie in the travel path of the punch assemblies. Only one (1) punch assembly should be connected to the electrical harness.
    
    
14. Restart the Imagesetter. No error messages should appear on the operator display panel. Possible error messages include: PUNCH UNIT STUCK or STARTUP FAILED.
    
    
15. Enter the punch utilities menu on the display panel and run the Punch Sequence option. Check that all punch assemblies are working correctly.
    
    If the system is not working and an error message appears, check the connecting harness and ensure it is routed properly (Refer to the Note in Step 7). Check that NVM parameters have been entered correctly. You will need to restart the Imagesetter in order to release the software from its error condition.
    
    
16. If punch units or punch rods are moving too quickly or too slowly, adjust the air flow controllers. Note that final air flow adjustment is performed later.
    
    
17. When the first punch assembly is operating smoothly, connect the other punch assemblies to their respective electrical harnesses. It is recommended to test the Punch Sequence (Step 15) after connecting each of the punch assemblies.

Trial Inspection

18. Load 1180 mm of film into the Imagesetter and perform a Punch Sequence. Unload the film and check the punch holes for the following general characteristics:
    
    No mismatch in punch hole type order.
    
    Correct distances between punch holes, as specified in the customer-approved layout. (Use the customer's pinbar as reference.)
    
    Correct distance between the first punch (P1) and the film edge (dimension Py on the Punched Film Layout Form).
    Hole surface quality:

• Smooth edge
• No sign of scratches around the holes on either side of the film
• No sign of plucking around the holes

Check for oil marks on the film around the punch holes. If stains appear, clean the punch assembly intensively and check that the air system filter and dryer are connected.

In the event of punch hole placement problems, return to the punch assembly installation procedure and make all necessary corrections. Be sure to readjust affected units for all placement dimensions (radial distance, orientation angle, etc.) If you must move more than one punch assembly, choose carefully the units to reinstall, taking into consideration both ease of access and minimum adjustment.

Note: In the event a substantial difference exists in punch hole distance between the customer's pinbar and the customer-approved punch layout, consult with the CreoScitex specialist.