letterpress > monotype > hardware installation and testing

hardware installation and testing

Created by hww3. Last updated by hww3, 7 years ago. Version #9.

Additional supporting material and photos are available from the following website: http://bill.welliver.org/dist/monotype/installation

These instructions describe interfaces that include an electro-magnetic cycle sensor. Current interfaces include a newer optical cycle sensor. For installations using this newer style of sensor, skip steps 14 through 18 and in their place, refer to the procedure in the following document: optical cycle sensor installation

When you are finished using the caster control interface, it is best to unplug the power adapter. This will ensure that any valves are de-energized. Similarly, do not leave the interface in the "all signals on" state longer than necessary. The "all signals on" state typically occurs when the interface board is first connected to power. The caster control application shuts off all signals when starting.

Getting Started

Items included in interface kit:

• Interface assembly (electronic interface, pneumatic manifold and valves and air bar adapter
• Air bar adapter clamps (pair)
• Cycle sensor package (see below for details)
• Air bar adapter installation pins (2)
• Universal Power supply
• USB Cable
• Machine cycle sensor spacer
• Hanging strap
• Wire ties

Tools and supplies you will need

• Screws for hanging interface assembly (or other means of hanging)
• Air supply routed to interface assembly (via the 1/8" NPT female port)
• Macintosh computer running Mac OSX 10.4, 10.5 or 10.6
• IEC power cable
• Straight bladed screwdriver
• Hex key (supplied for non-US users)

Installation Procedure

This installation procedure should only be performed on a caster with the pot cold and when the motor is not running.

Normally, this procedure will take from 10 to 15 minutes, however the following initial installation instructions include a number of extra steps that will verify that all components of the interface are working and are properly adjusted.

Please carefully read through the following procedure completely before beginning the installation process.

1. Carefully remove all items from packing and ensure that no damage has occurred during shipment.

2. Make sure that the threaded ring on each pneumatic valve has not become loose during shipment.

• The rings should be finger tight. Also, verify that all connectors are properly attached to the interface board and air valves. One pair of yellow spade connectors should be unused, near the position of the missing 32nd pneumatic valve.

3. Hang the interface assembly using hanger strap and screws, making sure that the air bar adapter reaches the air tower on the caster.

• The cables and hoses to the air bar tower should not be tightly stretched. Allow the air bar adapter to hang.

4. Attach the interface board using the black wire tie attached to the pipe connecting the two sets of pneumatic valves.

• The circuit board should be centered between the air valves and should not touch anything.
• Attach the cycle sensor connector (a beige plastic plug connected to the yellow and white wires) to the interface board; next to the 4th air valve port.
• Attach each ribbon cable to the appropriate port on the interface board. The cables and ports are numbered 1 through 4. Note that the connectors have a key centered on one edge, and this should be positioned so that the single centered cutout on the interface port are aligned. When looking at the board to read the writing on it, the red conductor on each cable should be on the left-hand side.

5. Connect your compressed air supply to the interface assembly (20-30 PSI) and verify that there are no leaks. Tighten any loose connectors or valves.

• If air is leaking around a valve, loosen the threaded ring on the pneumatic valve and use a pin wrench to tighten the valve on the manifold. Loosening the threaded ring will allow the top half of the valve to move independently of the bottom half. Tighten the valve gradually, making it only tight enough that the leak stops. You might have to tighten the threaded ring on the valve in order to make this determination. Once the valve has been tightened, make sure that the top half of the air valve is properly aligned. Tighten the threaded ring.

Do not completely loosen the threaded ring, as the valve will separate and the very small components inside will fall out!

6. Remove the second and second from last air fittings (marked with yellow and black paint) from the air bar adapter. Gently insert the air bar adaptor installation pins through the holes until they extend past the gasket approximately 1/2 inch (10 mm).

7. Lift the air bar clamp and disable the paper feed.

8. Place the air bar adapter on the caster.

• Use the installation pins to ensure correct positioning. Be careful not to scratch the air tower or bend the installation pins. The installation pins should slide into the corresponding air passages on the air tower and hold the air bar adapter in position on the air tower.

9. Gently insert the air bar adapter clamps on either side of the air bar adapter.

• The clamps should slide between the sides of the air tower and the paper advance sprocket. The clamps should slip over the air bar shaft and hook into place. Do not use force when trying to insert the clamps; they should slip into place when held in the correct position.

10. Bring the air bar adapter clamps into place and tighten.

• With the air bar adapter clamps hooked to the air tower, position them over the air bar adapter and gently tighten the clamping knob until it fits into the holes on the air bar adapter. Only tighten the clamping screws enough to provide firm pressure on the air tower. Gently wiggle the air bar adapter to make sure that it is properly seated over the air passages.

11. Gently remove the installation pins from the air bar adapter.

• You may need to use pliers to do this, but they should not be excessively tight. If they are, it may indicate that the air bar adapter is misaligned or that the installation pins have become bent. Loosen the air bar adapter clamps and try again.

12. Reinstall the 2 fittings you removed during step 5.

• Do not over-tighten the fittings: they should be snug, not too tight. Note that the correct connections are color coded with yellow or black paint.

13. Test the pneumatic valves and air bar adapter connection.

• Connect the USB connection to the computer and connect the power adapter to the interface board. The power LED and all 31 air signal LEDs should light. If they do not, verify that power is correctly connected.
• Launch the Caster control application from the computer connected to the interface board. All 31 air signal LEDs should turn off but the power LED should remain lit.
• If they do not, or you get a message from the Caster control application indicating that the interface is not present, quit the application and verify that the USB cable is properly connected. If, after restarting the caster control application, the problem remains, disconnect the USB cable and power from the interface board and contact me.
• From the "Interface" menu of the Caster control application, choose "Manual Pin Control". The Manual Pin Control window will appear.
• Test the pneumatic valve for each air signal by clicking on the checkbox for that signal. The LED for the corresponding air signal should light, and you should hear a very soft "click" coming from the pneumatic valve bank. Turn the air signal off by un-checking the check-box. You should hear another soft click as the valve shuts off and the LED for that air signal should turn off.
• If the LED lights, but you do not hear the valve turn on, shut the valve off and turn it on again. If the valve still does not turn on, verify that the valve is properly connected to the interface board (there should be 2 yellow spade connectors) and that the threaded ring on the valve is tight.
• To locate the valve in question, look at the air signal LEDs. Notice that they are grouped into 3 sets of 8 and one set of 7 by a white line on the interface board. These 4 groups correspond to the ribbon cable on directly below each air signal group. Each ribbon cable has 16 conductors, with a pair going to a each valve in that group. The red conductor is always the first signal, and they continue in order.
• Finally, turn the air to the interface assembly on and test each air signal. Make sure that the corresponding air pin or spacing signal is activated. Note that you may need to run slightly more air pressure (usually 20-30 PSI) than normal due to air line losses over the longer air path from the pneumatic assembly. Check to make sure that there are no leaks at the air fittings or around the gasket. Tighten or adjust any fittings or the air bar adapter clamps as needed.

14. Attach the cycle detector magnet to the air bar clamp activating rod.

• Remove the 2 hex screws from the clamping collar and place the 2 halves of the clamping collar over the activating rod. The detector magnet bracket should be oriented so that it forms an upside-down "L".
• Reinsert and gently tighten the hex screws. The assembly should be just loose enough that the collar can be slide up and down to adjust its position.

15. Attach the cycle detector sensor to the air tower.

• Using the provided "C" clamp, attach the cycle detector sensor to the air tower. Align the sensor with the sensor magnet. Tighten the "C" clamp enough that the sensor does not move.

16. Adjust the cycle detector sensor gap.

• Slide the sensor detector magnet down the activation rod. Slowly turn the caster over by hand until the activation rod has moved completely up in its travel (as though the air bar clamp were being released over the paper on the air bar.)
• Using one of the installation pins, set the gap between the cycle sensor and the sensor magnet, slide the sensor magnet up the activating rod until the gap is taken up. That is, the gap between the sensor and magnet should be just slightly more than the thickness of the installation pin.
• Verify that the sensor and magnet are aligned, and tighten the hex screws so that the collar is tight on the activating rod.

17. Attach the cycle sensor cable to the interface board.

• The sensor cable plugs into the 2 pin socket next to the last ribbon cable on the interface board. Press the connector in until it clicks into place.

18. Verify that the sensor is correctly installed

• Attach the USB cable and power connection to the interface board.
• Start the caster control application. All air signal lights should go off.
• Slowly cycle the caster by hand and watch the "Cycle" LED on the interface board. It should go out when the caster is about to close on the air pins and position the mat case. The cycle LED should be lit when the caster is out of casting position and the gap between the cycle sensor and magnet has opened. You can adjust the timing by moving the cycle detector magnet closer or farther from the detector sensor.
• If the cycle light does not go out, verify that the sensor is connected properly and try again.
• If the cycle light still does not activate, you may need to adjust the spacing between the cycle detector and the cycle detector magnet. You can verify that the cycle detector is working by moving the detector magnet up and down on the activating rod.

19. Using the Caster control application, test the functionality of each "pin".

• From the "Interface" menu, choose "Manual Pin Control".
• Ensure that the interface is connected to the computer and that the power to the interface board is turned on.
• Turn on the air to the interface assembly.
• Tick the "Ignore cycle sensor" check box.
• Test each signal in turn, by ticking the corresponding box next to the signal.
• Ensure that the signal enabled activates the corresponding pin or piston. Refer to the diagram of pin locations to determine which pin is which.
• When the signal is confirmed, un-tick the box and move to the next signal.

20. Using the Caster control application, load and run the test ribbon.

• Click on the load button and select the "test.rib" file.
• Ensure that the interface is connected to the computer and that the power to the interface board is turned on.
• Turn on the air to the interface assembly.
• Disengage the pump mechanism and start the caster.
• Click on the "Start" button. The interface board should detect the cycling of the machine and send the next code to the caster. Verify that the caster control program is sending new codes with each machine cycle (the test ribbon is configured so that a different code is sent to the caster for each cycle. It is not designed to produce usable caster codes).
• Click the "Stop" button in the caster control application. The interface should stop sending codes to the caster.
• Stop the caster.

21. Congratulations, you've successfully installed the Monotype control interface.

Not categorized | RSS Feed | BackLinks