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CHAPTER 14: MASTER MAKING SECTION

CONTENTS

1. Theory of Operation
1. Master Making ....................................................................................................... 1
2. TPH Positioning .................................................................................................... 3
3. Thermal Power Safety Switches ............................................................................ 5
2. Removal and Assembly
1. Write Roller ........................................................................................................... 7
2. Thermal Print Head (TPH) ..................................................................................... 8
3. TPH Position Sensor ............................................................................................. 9
3. Adjustment
1. Thermal Power of Thermal Print Head ................................................................ 11

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MASTER MAKING SECTION
THEORY OF OPERATION

1. Theory of Operation
1. Master Making
When the START key is pressed for master making, the Drum rotates to remove the master on the
Drum.
At the same time the TPH-CTL signal is turned ON to supply heating power to the Thermal print
head [A].

1. Start of the Master Making

> While the Drum is rotates to remove the master on the Drum, the Write pulse motor [D]
activates and starts feeding the master material from the master roll 50 ms after the Drum
rotates 100 from the first Drum Position-A.
> At the same time the original starts feeding through the ADF unit for scanning.
> As the Write pulse motor activates and feeds the master for 5mm, the Read & Write start
signal is turned ON and the Thermal print head begins making image on the master material.

2. End of the Master Making

> After a certain set time, the Master tension plate solenoid activates and swings down the
Master tension plate.
> The master runs through the Master tension plate and as the Master tension plate swings
down, it gives tension on the master while the master is loaded on the Drum.
> Either the original scanning ends or if the Write pulse motor activates for the maximum master
making length, both the TPH-CTL signal and Read & Write start signal turn OFF.
> The Write pulse motor is still activated until full length of master material is transferred.
The Write pulse motor then stops and completes the master making process.

A:Thermal print head (TPH)

B:Write roller D
C:Master roll
D:Write pulse motor
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MASTER MAKING SECTION
THEORY OF OPERATION

1. Master Making Timing Chart

Scanning is completed, or
Write pulse motor has rotated
maximum master making
length.
Cutter unit
3 activates
Original IN sensor Detecting original

Clamp motor OFF

ON

Read pulse motor

ON
1
4
Write pulse 180ms
motor ON
2 4769 pulses *1
10.87mm
14pluse
TPH-CTL signal
MAX 4141pulses *1

1 The Write pluse motor and the Main motor activate after 180 ms the Clamp motor goes off.

2 After the Write pulse motor activates 14 pulses (1.2 mm), the TPH-CTL start signal turns ON and
master making starts. The original scanning starts at the same time.

3 After the Scanning is completed or Write pulse motor has rotated maximum master making length, both
the Read/Write start signal and TPH-CTL signal are turned OFF to end the master making.
*1: The maximum master making length of the Write pulse motor is 4141 pluses or 10.87mm plus the
pluses until the original throughing out the Original In sensor.

4 After the TPH CTL signal off, the Write pulse motor keeps turning until one full size master length (4769
pulses) of master material is moved forward.
The Write pulse motor then turns OFF and the Cutter unit cuts the master material.

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MASTER MAKING SECTION
THEORY OF OPERATION

2. TPH Positioning
The TPH [C] moves down and up when master feeding is necessary or the master making process is
ended.
When the TPH unit [C] is at the home position, the TPH unit detouch the Write roller [B].
When the Master making starts, the TPH unit [C] is lowered by the Write pulse motor [D].
Rotation of the Write pulse motor is transferred to the TPH position cam [E] via geras on the Master
making unit.

1. TPH position sensor

>The TPH position sensor [A] checks whether if the TPH stays upper or not.
>If the light path of the TPH position sensor is changed from "unblocked" to "blocked", the machine
assums that the TPH stays at upper position.(The TPH detouchs the Write roller)
>If the light path of the TPH position sensor is changed from "blocked" to "unblocked", the machine
assums that the TPH stays at lower position.(The TPH touchs the Write roller)

A
Spring force

TPH Sensor opened TPH

A Sensor blocked
detouching Touching

B
C

D
D

A:TPH positioning sensor

B:Write roller
C:TPH unit
D:Write pulse motor
E:TPH position cam
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MASTER MAKING SECTION
THEORY OF OPERATION

2. TPH Positioning Timing Chart

1. From Original set to Preparation of Scanning

Read pulse motor ON OFF ON

ON CW
ON CCW
White pulse ON CW
motor

TPH position
sensor Blocked

2. From Master making to Master cutting

Master making ended Master cutting

Read pulse motor

White pulse
motor OFF ON CW
ON CCW

TPH position
sensor OFF

Blocked

Blocked

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MASTER MAKING SECTION

THEORY OF OPERATION

3. Thermal Power Safety Switches

1. Safety Switches
> The actuators of all four safety switches must be pressed in order to feed electrical power to
the TPH unit.
> These four switches also acts as Main motor safety switches.

A:Master removal unit safety switch

B:Guide plate safety switch
C:Master making unit safety switch
D:Separation unit safety switch

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MASTER MAKING SECTION
REMOVAL AND ASSEMBLY

2. Removal and Assembly

1. Write Roller
1. Disconnect the power supply from the machine.
2. Open the Master making unit and remove the Master roll.
3. Remove front side of Lock ring fitting on the Whit roller shaft and remove the collar and the metal
from the shaft.
4. Remove the Write roller ass'y by lifting the ass'y from the machine.

Precaution in Assembly
> Match the flat part of the Metal [C] on the rear side to the E-ring fitting to the Write roller ass'y
[B] shaft.(refer to below photos a and b)

C
A
FRONT

Flat part

B D

a. Corrct position

b. Incorrct position

A:Lock ring
B:Write roller ass'y
C:Metal
D:Collar
REAR

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MASTER MAKING SECTION
REMOVAL AND ASSEMBLY

2. Thermal Print Head (TPH)

1. Disconnect the power supply from the machine.
2. Open the Master making unit.
3. Disconnect the TPH connectors [A] out from the TPH ass'y [D].
4. Remove the screw of the Grand wire [B].
5. Remove the TPH ass'y screws [C].
6. Slide the TPH ass'y [D] up to release from the Master making unit.
7. Remove two mounting screws of the TPH position plate [E] from the TPH ass'y [D].

C A A B A
A B E

A:TPH connector
B:Ground wire
C:TPH ass'y screw
D:TPH ass'y
E:TPH position plate

D
Precautions in Removal
> Do not touch the Connector pins [A] on the TPH ass'y [D], as static electricity may damage the
TPH ass'y [D].
> Do not contact the heat emitting portion of the TPH ass'y [D] against hard surfaces.

Adjustment after Assembly

> Thermal power adjustment of the TPH must be done when replacing the TPH ass'y.

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MASTER MAKING SECTION
REMOVAL AND ASSEMBLY

3. TPH Position Sensor

1. Disconnect the power supply from the machine.
2. Open the Master making unit [D].
3. Remove the Springs [A] from the Master making unit [D].
4. Remove the the Master making upper unit cover [B].
5. Remove the Position sensor plate [C].
6. Remove the connector of the TPH position sensor [E].
7. Remove the TPH position sensor [E] from the Master making unit [D].

E A
B

A: Spring
B: Master making upper unit cover
C: Position sensor plate
D: Master making unit
E: TPH position sensor

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MASTER MAKING SECTION
ADJUSTMENT

3. Adjustment
1. Thermal Power of Thermal Print Head
Thermal power must be adjusted each time the Thermal print head is replaced.

1. Disconnect the power supply from the machine.(unpluge the power cable)
2. Remove the Front cover. (See page 1-6)
3. Connect a Voltmeter to No.1 and No.3 pins of the connector CN008 of the Power supply PCB.
4. Connect the power cable back to the machine.
5. Set up Test mode No.51. (refer to page APX(2)-1)
6. Press "Start" button to enable the TPH power supply.
7. Check to see that the Voltage reading on the Voltmeter equals to the voltage setting on the chart
shown in the next page for the new Thermal print head on the machine with the new resistance
Ω) setting.
(Ω
The resistance (Ω Ω) of the new TPH is found printed on a seal attached on the TPH itself.
8. If the voltage on the Voltmeter does not match with the voltage on the chart in the next page, turn
the Volume adjust knob, of which can be seen throgh the protection cover of the Power suplly
PCB until the corect voltage reading is obtained on the Voltmeter.
9. TPH voltage can be adjusted by the VR named "NORMAL Adj." (lower position) & "FINE Adj."
(upper position).
Firstly adjust the TPH voltage by the NORMAL Adj. VR and precise adjustment can be done by
FINE Adj. VR.
10. After the adjustment is done, exit from the Test mode.

Power supply PCB

No.1 pin No.3 pin

CN008

FINE Adj. VR

NORMAL Adj. VR

* TPH Adjustment Table is the next page

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MASTER MAKING SECTION

ADJUSTMENT

TPH Adjustment Table

All KS Models All KS Models

Ω)
Resistance (Ω Voltage (V) Ω)
Resistance (Ω Voltage (V)
1360 ~ 1373 16.1 1697 ~ 1715 18.0
1374 ~ 1390 16.2 1716 ~ 1734 18.1
1391 ~ 1407 16.3 1735 ~ 1753 18.2
1408 ~ 1424 16.4 1754 ~ 1772 18.3
1425 ~ 1442 16.5 1773 ~ 1792 18.4
1443 ~ 1459 16.6 1793 ~ 1811 18.5
1460 ~ 1477 16.7 1812 ~ 1831 18.6
1478 ~ 1494 16.8 1832 ~ 1840 18.7
1495 ~ 1512 16.9
1513 ~ 1530 17.0
1531 ~ 1548 17.1
1549 ~ 1566 17.2
1567 ~ 1584 17.3
1585 ~ 1603 17.4
1604 ~ 1621 17.5
1622 ~ 1640 17.6
1641 ~ 1658 17.7
1659 ~ 1677 17.8
1678 ~ 1696 17.9

Caution in Adjustment
> The new Thermal print head must be installed before making above adjustment.
> All four Thermal power safety switches (page 14-5) must be pressed to get the correct
voltage reading on the Voltmeter.

Results of Incorrect Adjustment

> If the voltage is too High:
The solid print image will be deformed and the heating elements of the Thermal print head will
be damaged from overheat.
> If the voltage is too Low:
The heat from the Thermal print head becomes too weak and the thin lines cannot be
reproduced clearly.

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