Installing a plate detector on ThermoFlex Mid and Narrow

Description

This Procedure describes how to install and adjust the Plate Detector (or Anti-Collision Detector).The Plate Detector prevents collisions between the Carriage Head and the plate. Collision can occur when a plate whose thickness does not match the set thickness value is mounted on the drum, or when the plate was not properly attached to the drum.

Prerequisites

• Verify that the machine has the Plate Detector wiring required for the Optic Sensor. (See Figure 1, below.)
• Verify that the Lotem software version 1.20.09 or higher is installed.
• Verify that the FCO for the loading/unloading tray is implemented.

Hardware Installation

• Lower Optic Fiber - Mounted in a fixed position, it acts as a transmitter.
• Upper Optic Fiber - Moveable for fine-tuning, it as a receiver.
• Optic Sensor - Connects to both Optic Fibers on one end and to the Plate Detector (Molex Plug) on the other end, and signals the Software.

Replacing the Nozzle

Prior to the installation

• For ThermoFlex 4045, you must replace the Light Detector Cover to prevent it from colliding with the Plate Detector

To replace the nozzle:

1. From the Lotem application, move the Carriage to the middle of the drum.
   ThermoFlex 2630 - move the carriage to 400
   ThermoFlex 4045 - move the carriage to 600
   
   
2. Load a plate of the size and thickness that the customer usually works with on the drum and secure it with masking tape.
   
   
3. In the Media Definition dialog box, check the Focus value defined for that plate thickness, and move the Focus Motor according to that value.
   
   
4. Open the doors of the machine:
   • 2630 - From the Lotem application, open the front door. Then manually open the right door and remove the front panel.
   • 4045 - From the Lotem application, open the front and back doors. Then manually open the right door and remove the front panel.
     
     

   Note: The right door provides access to the L-Box.
   

5. Exit the Lotem application.
6. Turn off the machine, and then turn off the main power to the machine.
7. Open the Loading/Unloading tray by lifting the handle.
8. Remove the black cover (above the L-Box) by removing the four screws.
9. From the right side of the machine, look for wiring labelled "Plate Detector".
   
10. Connect the Molex of the Optic Sensor supplied in the kit to the "Plate Detector" Molex plug.
11. Disconnect the black hose from the Nozzle Assembly (See Figure 2.)
12. Disassemble the Nozzle Assembly from the carriage by removing the two screws.
    (See Figure 2.)
    
13. Install the new Nozzle Assembly (which includes the Plate Detector) from the FCO kit 0.5 mm away from the plate (for a detailed procedure, see Appendix A) and secure the two screws.
14. Secure the black hose to the Nozzle using RTV.
    

To Connect the Optic Fibers

1. Thread the Optic Fibers, which are part of the FCO kit, through the orange hose and route them through the Fiber Optic Chain to the Carriage.
   
2. Route the upper Optic Fiber along the black hose to the Nozzle Assembly,and the lower Optic Fiber under the Spring Leafs to the Nozzle Assembly.
   
3. Position the Optic Fibers as shown in Figure 5, verify that they do not protrude, and secure them by tightening the screws.
   Important: Place the upper Optic Fiber with the hollow facing down, and the lower Optic Fiber with the hollow facing up (the hollows should face each other),
   as shown in Figure 6.
   
   
4. Turn on the main power and then turn on the Lotem.
   Note: Do not install the panels.
5. Remove the Optic Sensor Cover.
6. Push down the Handle. (See Figure 7.)
7. Insert the ends of the Optic Fibers into the Optic Sensor. The lower LED in the Nozzle Assembly is on.
   If the upper LED is on, switch the Optic Fibers.
8. Push up the Handle to lock the Optic Fibers in place.
   
   

Adjustment Procedure

To set the Optic Sensor Switches:

1. Using the screwdriver from the FCO kit (see Figure 8), set the switches on the Optic Sensor according to Table 1, below.
   
   
   
   

   Switch name	Set to:
   Fine / Turbo	Turbo
   Off.D / On.D / Off	Off
   D.On / L.On	D.On

   Table 1 - Optic Sensor Switch Settings
   
   Note:If the adjustment is not correct, the Red LED in the Optic Sensor may be on constantly.
   
   
2. Hold a 7/64" Allen key between the transmitter and the receiver. The red LED in the Optic Sensor is on. When you remove the Allen key, the red LED is off.
3. Adjust the Nozzle position (See Appendix A).
4. Manually turn the drum and check that the red LED is not on. The LED should not be on even when the plate is in front of the carriage. If the red LED is on, reduce the sensitivity of the Optic Sensor using the screwdriver.
5. Place five pieces of masking tape one on top of another to form one thick piece of tape and tape it horizontally over the top or bottom edge of the plate.
6. Manually turn the drum and check whether the red LED in the Optic Sensor is on when the tape passes between the transmitter and the receiver, which means that the Optic Sensor detects the excess thickness.
7. Remove the thick piece of tape, manually turn the drum and check whether the red LED is on.
8. If the red LED is on, open the 7/64" Allen screw, and move the upper Nozzle Assembly forward until the red LED is off.
9. Tighten the 7/64" Allen screw. (See Figure 8.)
   
10. When the adjustment is completed, return the Optic Sensor cover to protect the Sensor.
11. Secure the black cover (above the L-Box) with the four screws you removed earlier.
12. Close the Loading/Unloading tray.
13. Turn on the main power to the machine, and then turn on the machine.
14. Start up the Lotem application.
15. Close the doors of the machine.

Appendix A - Adjusting the Nozzle Position

Description
The following procedure describes how to adjust the Nozzle position so that the Nozzle is 0.5 mm from the plate.

To adjust the Nozzle position:

1. Load a plate of a known thickness on the drum.
2. In the Media Definition dialog box, check the Focus value defined for that plate thickness, and move the Focus Motor according to that value.
3. Cut five strips of the same size (about 1" X 4") of the milky-colored protective layer used for the plates, and place them one on top of the other to form a 0.5mm jig.
4. Place the jig between the plate and the vacuum nozzle.
5. Loosen (but do not remove) the two screws on the Nozzle Assembly. (See Figure 10.)
   
6. Move the Nozzle Assembly back and forth until the jig enters the space between the Vacuum Nozzle and the plate smoothly, but without extra space.
7. Remove the jig.
8. Tighten the two screws that you loosened in step 5.
9. Insert the jig between the Vacuum Nozzel and the plate to verify that the distance did not changed after the you tightened the screws.