Focuskit BG

Doc. No.
Date: 27-Nov-01
MKT-0505-AI
Subject: Writing Head Focus Toolkit User Manual
This is a product/process level document.

REV. REV. DESCRIPTION ECO NO. DATE NAME
00 Kit Instructions 7635 Neev Elbaz
Field Support by: Neev Elbaz

R & D Approved by Jonathan Zur
Engineering Approved by: Amir Weinreb
Service Approved by: Aaron Lubelski
Written by: Moshe Kosower
Configuration Control: Charles Margy
Indigo Ltd. Proprietary and Confidential
P.O. Box 150
Kiryat Weizmann, Rehovot 76101 Israel
©Copyright Indigo, 2000. All rights reserved.
CONFIDENTIALITY NOTICE
This document contains valuable trade secrets and confidential information of Indigo. Nothing
herein may be copied, reproduced or distributed in any form or any medium, or disclosed to any
third party in any manner, without prior written authorization of Indigo. The copyright notice which
appears above is purely precautionary, and shall not be deemed to constitute publication or intent
to publish, in whole or in part.
PROPRIETARY AND CONFIDENTIAL FILENAME: FOCUSKIT.DOC PAGE 1OF 29

MKT 0505 Writing Head Focus Toolkit User Manual
Writing Head Focus Toolkit

User Manual
MKT-0505-AI
November 2000
PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 2 OF 29

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1. Overview ......................................................................................................................4
2. Software Installation ...................................................................................................6
3. Configuring and Testing the Software ........................................................................6
Configuring the FINS Gateway Service Manager ..................................................... 6
Testing Communication............................................................................................ 10
Testing the Software................................................................................................. 11
4. Installing the Kit on the Machine (Not for UltraStream) .......................................12
Installing SOS Stepper Motor .................................................................................. 13
Installing EOS Stepper Motor.................................................................................. 15
Installing the Paper Feed Sensor (Sheet Fed Machines Only )....................... 16
5. Focus Procedure.........................................................................................................17
Printing the WHFocus job ........................................................................................ 17
Printing the Focus Sheets (Sheet Fed Machines ) ............................................ 20
Printing the Focus Sheets (Web Machines ) ....................................................... 21
Scanning the sheets .................................................................................................. 22
Raising the Writing Head to the Optimal Focus Position ....................................... 28
Final Inspection ........................................................................................................ 28
Post-Focus Adjustments ........................................................................................... 29
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Figure 1 Toolkit Contents...........................................................................................4
Figure 2 Suitcase Connector Panel ..........................................................................12
Figure 3 Front Focus Adjust Mechanism .................................................................13
Figure 4 Installing the SOS Stepper Motor .............................................................14
Figure 5 Rear Focus Adjust Mechanism ..................................................................15
Figure 6 Installing the EOS Stepper Motor .............................................................15
Figure 7 Installing the Paper Feed Sensor ..............................................................16
Figure 8 WHFocus Job..............................................................................................18
Figure 9 Auto Focus Window–Sheet Fed Setting ....................................................19
Figure 10 Auto Focus Window–Web Setting............................................................21
Figure 11 Connecting the Scanner to the Laptop ....................................................22
Figure 12 Scan Window ............................................................................................23
Figure 13 Scanner Window ......................................................................................24
Figure 14 Inserting a Sheet in the Scanner .............................................................25
Figure 15 Scanning Error Message Caused by Feeding the Sheet after Pressing the
START/CANCEL Button ..................................................................................26
Figure 16 Measurement Error Message...................................................................27

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STEPPER MOTORS
FEED SENSOR
CABLES
SCANNER
POWER
SUPPLY
EXATAPE
SCANNER
STEPPER
MOTOR
DRIVERS
MAIN
POWER SUPPLY
SUITCASE
PLC
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The Writing Head Focus Toolkit facilitates rapid and accurate focusing of the
Writing Head. It should be used when a new Writing Head or Press is installed
and when a decision is to be made to return a Writing Head to Indigo. All
queries should be referred to the local service center.
The kit includes the following components (Figure 1):
SOS Stepper Motor: Fits on front Focus Adjusting Screw
(E-Print and TurboStream only)
EOS Stepper Motor: Fits on rear Focus Adjusting Screw
Paper feed Sensor: Fits in front of Paper feed cam
Control Unit: Suitcase containing power supply,
control unit, and stepper motor drivers
Cables: Power, RS232, cable to stepper motors,
sensor cable, scanner cable
Scanner: Used to scan focus job
Scanner power supply: Universal, adapts automatically to all
local voltages
Exabyte: Contain new focus job (for E-Print)
CD ROM: Software and new focus Job (see below)
Scanner calibration card: Used to calibrate scanner

(2) Stepper motor timing belts: Spare

Reference focus sheets and Used to test the software and scanner
graph:
Caution: Make sure that the unit is set for the correct local voltage before turning
on the power.
FNote: Adapters for local power outlets are not supplied.

The paper feed sensor is designed for TurboStream family sheet-fed machines
only. It automates the process of lowering the Writing Head after each sheet is
printed. After analysis by the software and scanner, the stepper motors
automatically raise the Writing Head to the best focus position, and the software
determines the optimum Writing Head temperature.
In the Omnius (web) machines, the Writing Head is manually lowered after each
sheet is printed. After analysis by the software and scanner, the stepper motors
automatically raise the Writing Head to the best focus position, and the software
determines the optimum Writing Head temperature.
In the UltraStream and in TurboStream machines with Writing Head version
51, the stepper motors and sensor are not used. Lowering and raising the
Writing Head is manual, and the software is only used to analyze the printed
sheets and determine the optimum Writing Head position.
The kit is intended for use with a PC or laptop with at least:
• Pentium 160
• Windows 95/98
• 16 MB Ram (32 recommended)
• At least 100 MB free hard disk
• CD ROM drive
• Recommended screen resolution 1024/768

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The CD ROM contains the following directories. It is important to install the
software in the order listed below. Accept all the default screens except for the
FinsGateway products window as shown below. Reboot the computer after
installing all the software.
Fuji: Scanner software. Must be installed on your
computer/laptop. Click on Setup and follow the instructions.
Fgw2 PLC software. Must be installed on your computer/laptop.
Click on Setup and follow the instructions. Select all the
products as shown below:
Compolet/ PLC software. Must be installed on your computer/laptop.

disk1: Click on Setup and follow the instructions.
WHFocus: WHFocus software. Must be installed on your
computer/laptop. Click on Setup and follow the instructions.
Acrobat: Acrobat reader. Install on your computer/laptop if not
already installed.
Focus Job: Copy to machine if not already there. For E-Print machines,
take the job from the Exabyte.
Reboot the computer.
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•1. Start the WHFocus Software.
•2. Select the Tools>PLC Communications Setting menu item.
The FinsGateway Service Control Manager window will be displayed:

•3. Deselect SCM automatic run on logon

•4. Select SerialUnit and click on the Start button.
•5. Click on the Property button to display the Service Properties window.
Select Auto: Automatic start and click OK.
•6. Select CPU_UNIT and click on the Start button.

•7. Click on the Property button to display the Service Properties window.
Select Auto: Automatic start and click OK.
The FinsGateway Service Control Manager window should look as
follows:

•8. Click on the icon the display the Network Navigator.
•9. Click on the Add button and enter data in the fields as shown below and
click OK:
Click Yes for Change Routing Tables.

•10. In the Network Navigator window, select 1 serial unit and click on the
Property button.
•11. In the Properties window, enter the data in the Communication Unit tab
as shown below and click on Apply:
Click Yes for Restart Serial Unit Service.

•12. Enter the following data in the Network tab:
•13. In the Nodes tab, Delete the existing node and the press Add.
Enter the following data in the Add/Edit Serial Node window.
•14. Click on Apply.

•15. Click on Yes to restart serial unit service.
•16. Click on Yes to change the routing tables.
•17. Close the window.
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•1. Connect the computer RS232 port to the suitcase.
•2. Connect the suitcase power and turn ON.
•3. Start the WHFocus program..
•4. Select the Tools>PLC Communication Test menu item.
If there is a communication problem, an error message will be
displayed.

Check the RS 232 connection, power switch, and power connection.

.I If required, reconfigure the software.
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•1. Make sure that the scanner is connected to the computer as shown in
Figure 11. If not, shut down the computer, connect the scanner, and
restart the computer.
•2. Start the WHFocus program and scan the reference sheets.
Follow the instructions on page 22.
The graph that you get should be similar to the reference graph.

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Caution: Exposure to strong light will damage the PIP. Dim or turn off the
lighting when opening the machine.
FImportant: The Writing Head focus is sensitive to temperature. Allow the machine
to work for at least 1½ hours to reach equilibrium temperature before focus.
•1. Arrange the suitcase on a suitable working surface near the paper exit
side of the machine.
•2. Make sure that the suitcase main switch is OFF and connect the main
power cable to the suitcase.
•3. Connect the RS232 cable between the suitcase and the laptop
(Figure 2).
•4. Connect the stepper motors cable to the suitcase (Figure 2).
•5. Connect the sensor cable to the suitcase (Figure 2).
•6. Turn the suitcase main switch ON.
SENSOR MOTORS
RS232
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OPEN SECURING
LOOSEN SKEW NUT
ADJUSTING
SCREW
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•7. Remove any existing tiewraps from the Writing Head.

•8. Loosen one of the skew adjusting screws and open the securing nut on
the front focus adjusting mechanism (Figure 3).
Make sure that the screw is free to turn smoothly.
Lightly lubricate the screw if required.
•9. Install the SOS stepper motor on the front focus adjust mechanism as
shown in Figure 4.
To align the stepper motor with the screw, turn the top knob slightly
Figure 4 and Figure 6.
Make sure that the motor is properly seated on the screw.
After installation, test by turning the top knob (Figure 6).
Tighten the securing knob (Figure 4).

ALIGN WITH SCREW
SECURING
KNOB
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OPEN SECURING NUT
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TURN KNOB TO
ALIGN MOTOR
AND TEST
SECURING KNOB
IF NECESSARY
LOOSEN SCREWS
AND MOVE BRACKET
ASIDE
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•10. Open the securing nut on the rear focus adjusting mechanism
(Figure 5).
Make sure that the screw is free to turn smoothly.
Lightly lubricate the screw if required.
•11. Install the EOS stepper motor on the rear focus adjust mechanism as
shown in Figure 6.
If required, loosen the screws and move the hose bracket aside as shown
in Figure 6.
To align the stepper motor with the screw, turn the top knob slightly
Figure 4 and Figure 6.
Make sure that the motor is properly seated on the screw.

After installation, test by turning the top knob (Figure 6).

Tighten the securing knob (Figure 6).
If you moved the hose bracket, make sure that the Slit Injector moves
freely (engage–disengage).
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2mm
LED
SENSOR
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12. Install the sensor on the machine opposite the Paper Feed cam as
shown in Figure 7.
The sensor should be about 2 mm from the cam.
13. Turn ON the suitcase.
Make sure that the LED is ON.
If the LED is not on, the sensor is too far away from the cam.
Tighten the securing nuts.
14. To test the sensor operation:
a. Lock the Input solenoid.
b. Manually turn the machine.
c. Make sure that the sensor detects the motion of the cam
The LED should go ON and OFF.

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•1. Close all the machine doors.
•2. Turn the laptop ON.
FImportant: The Writing Head focus is sensitive to temperature. Allow the Writing
Head to work for at least 1½ hours to reach equilibrium temperature before
focus.
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•3. Make sure that the print quality of the machine is good and that there
are no defects on the PIP or blanket.
•4. Adjust Image Placement and Skew.
•5. If the WHFocus job (Figure 8) is not on the machine, load it from the
CD or Exabyte.
•6. Perform Color Adjust. Use the Sequin LUT.
•7. Print one sheet of the WHFocus job for reference.

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29.4% BLACK
INSPECT FOR
BANDING

41.2%
USE TO
CALIBRATE
85% DENSITY

NOT IN
FIELD USE
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SCAN
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To Scanner
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•8. Start the WHFocus program on the laptop.

The following toolbar will be displayed.
•9. Click the AutoFocus Button to display the AutoFocus window.
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•10. Click the Unlock button.

•11. Click the Reset button.
The Max. Number of Steps should be 35. If it is a different value, set it
to 35.
•12. Press the Both Sides button.
•13. Print the WHFocus Job. While printing the job, use the ↑ key on the
laptop or the button on the screen to raise the Writing Head until
the Horizontal (Cross Scan) and Vertical (In Scan strips) at the bottom
of the sheet (Figure 8) are very dark and then stop printing.
Discard all the sheets that were printed.

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14. Make sure that the Automatic Operating Mode is selected (Figure 9).
15. Click the Start Automatic Down button and start printing the WHFocus
Job.
The sensor will detect the sheets, and the program will lower the
Writing Head 0.5 turn for each sheet that is printed.
During printing, as the Writing Head goes into focus, the strips will
lighten, and then darken again as the Writing Head goes out of focus
again.
16. When the Horizontal (Cross Scan) and Vertical (In Scan) strips at the
bottom of the sheet (Figure 8) are very dark again, stop printing.
Note the number of pages (number of steps) displayed on the screen.
The present position of the Writing Head will be the new 0 position. The
number of turns required to raise the Writing Head to the focus position
will be calculated from this position.
Caution: The End Down button must be pressed at the end of the procedure. If
the End Down button is not pressed, the Writing Head may be
accidentally raised or lowered and the zero position lost.
17. Click the End Down button on the Focus window ( Figure 9).
18. Close the Focus window.
Caution: Make sure that the sheets remain in the order that they were printed.
The sheets must be fed into the scanner in the reverse order of printing
(last out-first in). If one sheet is not in the correct order, the results will
not be valid and you will not be able to focus the Writing Head.
19. Cut the sheets along the dotted line as shown in Figure 8.

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20. Make sure that the Manual Operating Mode is selected (Figure 10).
21. Print one page of the WHFocus Job.
22. Click the Manual Down Button.
The program will lower the Writing Head 0.5 turn.
23. Print another sheet and click the MAnual Down Button again.
Continue printing and lowering the Writing Head in this manner.
During printing, as the Writing Head goes into focus, the strips will
lighten, and then darken again as the Writing Head goes out of focus
again.
24. When the Cross Scan and In Scan strips at the bottom of the sheet
(Figure 8) are very dark again, stop printing.
Note the number of pages (number of steps) displayed on the screen.
The present position of the Writing Head will be the new 0 position. The
number of turns required to raise the Writing Head to the focus position
will be calculated from this position.

Caution: The End Down button must be pressed at the end of the procedure. If
the End Down button is not pressed, the Writing Head may be
accidentally raised or lowered and the zero position lost.
25. Click the End Down button on the Focus window ( Figure 9).
26. Close the Focus window.
Caution: Make sure that the sheets remain in the order that they were printed.
The sheets must be fed into the scanner in the reverse order of printing
(last out-first in). If one sheet is not in the correct order, the results will
not be valid and you will not be able to focus the Writing Head.
27. Cut the sheets along the dotted line as shown in Figure 8.
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LAP-TOP
LAPTOP
POWER
TO SCANNER
POWER
SUPPLY
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•28. Connect the scanner to the laptop as shown in Figure 11.

Make sure that the scanner LED is lit.
•29. Select File>New or click the Scan button to open the scan window
(Figure 12).
•30. Enter all the relevant information in the Scan window fields.
You can enter values manually or select from the lists.

The lists can be edited from the Tools menu item.
FNote: This information can be corrected at any later stage through the Edit menu.
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•31. Click the Scanner button.

The scanner window (Figure 13) will be displayed.
Make sure that the scanner parameters are correct as shown in
Figure 13.
FNote: Make sure that Gray Level (arrow in Figure 130 is selected
FNote: If you are using the scanner for the first time on the computer/laptop, you
will be asked to calibrate the scanner when you first use it. Follow the
instructions on the screen.

PRESS MORE TO DISPLAY

THIS WINDOW
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LEFT GUIDE
(MOVABLE)
S TA
CA N RT / RIGHT
CE L
GUIDE
PAPER-IN
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Caution: Make sure that the left paper guide is adjusted to the paper width
(Figure 14). If the guide is not adjusted the sheet may skew when
passing through the scanner and cause erroneous results.
•32. Start feeding the sheets into the scanner as shown in Figure 14:
The last printed sheet should be fed first.
Make sure that you feed the sheets exactly in the reverse order of
printing.
To scan a sheet, gently push it into the scanner until you feel a slight
tug and hear a buzz. Then press the START/CANCEL button on the
scanner.
After the sheet is scanned, its image will appear on the screen.
The total number of sheets scanned is displayed at the bottom of the
sheet image.
If a page is not fed correctly, an error message will be displayed and the
sheet will not be counted. Click the Retry button and scan it again.

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If the image of the sheet does not seem to be normal but you did not get
an error message, you can press the Delete last page button and rescan
the sheet.
Close the Scanner window to display the Scan window.
•33. After scanning all the sheets, make sure that the number of pages
scanned is the same as the number of pages printed.
•34. Exit the Scanner window (Figure 13).
•35. Click the Save button in the Scan window (Figure 12).
The file will be saved in the format xxxxx-Fn.whf where xxxxx is the
Writing Head number and n is an index to keep track of different files
created for the same Writing Head.
Wait until the Writing Head focus graph is displayed.

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If there was an error in processing the data, Measurement Error will be

displayed at the bottom right of the graph (Figure 16).
This may be due to:
• Stepper motors not installed properly. Check the stepper motors and
if you discover that they are loose or not installed properly, install
them properly and redo the focus procedure.
• Full range not covered by printed sheets, i.e., the first or last printed
sheet was not dark enough. Redo the focus procedure.
• Sheets not fed in correct order or missing sheets. Redo the focus
procedure.
The Focus Graph will display the following data (Figure 16):
Focal Shift: Difference between linear cross scan and linear in
scan focal planes measured at center of format. If the
value is out of spec, it will appear in red. If the value
is out of spec, repeat the focus procedure. If you still
get an out of spec value, contact your local Service
Center for instructions.

Writing Head This will only appear for Writing Heads with
Temperature: temperature control.
Actual: The actual Writing Head temperature that
you entered. Make sure that it is correct, and if not,
use the Edit menu to correct it.
Optimal: The temperature required for optimal
performance of the Writing Head. If there is a
difference between the Actual and Optimal
temperatures, adjust the temperature controller as
required.
If you adjust the temperature controller setting, allow
at least ½ hour for each ∆ °C (e.g., for ∆ °C = 2° C, wait
1 hr) for the machine to reach equilibrium
temperature before printing a test job.
If you adjusted the temperature by 2° C or more,
repeat the focus procedure after waiting the required
time, to make sure that the actual optimal
temperature has been attained.
If the value is out of spec, repeat the focus procedure.
If you still get an out of spec value, contact your local
Service Center for instructions.
Screw Positions The number of turns required to raise the Writing
Head to achieve focus. This will be accomplished
automatically in TurboStream and E-Print machines.
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•36. Activate the AutoFocus window (Figure 9).
The Screw Positions values should appear in the Set fields of the
window.
•37. In the AutoFocus window, click on Unlock and Auto Focus Adjustment.
The stepper motors will raise the Writing Head to the correct focus
position.
•38. If you adjusted the Writing Head temperature, wait until the
temperature stabilizes, ½ hour for each °C.
•39. If you changes the Writing Head by 2° C or more, redo the focus
procedure.
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•1. Perform Color Adjust.
•2. Print a copy of the WHFocus job and inspect.
There should be minimal Writing Head banding (2.3 mm) visible in the
29.4% gray strip (Figure 8).

If there is slight banding visible, you may be able to correct it by slightly

adjusting the positions of the screws:
While printing the WHFocus job use the EOS Side, SOS Side, and ↑
and ↓ buttons to fine adjust the Writing Head position to achieve
optimal results.
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•1. Remove the stepper motors and sensor from the machine.
•2. Tighten the securing nuts on the front and rear focusing screws.
•3. Make sure that the temperature control unit cover is closed.
•4. Perform the following Writing Head adjustments:
Skew
Image Placement
Scaling
Deskew
•5. Send the graph file to whfocus@indigo.co.il.
The file is stored in the C:\WHFocus\WHF directory and has the
format xxxxx-Fn.whf where xxxxx is the Writing Head number.
•6. If a decision was made to return the Writing Head, it must be
accompanied with the following:
Focus graph
The strips that were scanned for focusing
The final print of the WHFocus job, with all the information filled in.

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Doc. No.

Subject: Writing Head Focus Toolkit User Manual

This is a product/process level document.

Field Support by: Neev Elbaz

PROPRIETARY AND CONFIDENTIAL FILENAME: FOCUSKIT.DOC PAGE 1OF 29

Writing Head Focus Toolkit

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 2 OF 29

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 3 OF 29

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 4 OF 29

(2) Stepper motor timing belts: Spare

FNote: Adapters for local power outlets are not supplied.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 5 OF 29

Compolet/ PLC software. Must be installed on your computer/laptop.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 6 OF 29

•3. Deselect SCM automatic run on logon

•6. Select CPU_UNIT and click on the Start button.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 7 OF 29

•8. Click on the icon the display the Network Navigator.

Click Yes for Change Routing Tables.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 8 OF 29

Click Yes for Restart Serial Unit Service.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 9 OF 29

•12. Enter the following data in the Network tab:

•14. Click on Apply.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 10 OF 29

Check the RS 232 connection, power switch, and power connection.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 11 OF 29

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 12 OF 29

•7. Remove any existing tiewraps from the Writing Head.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 13 OF 29

ALIGN WITH SCREW

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After installation, test by turning the top knob (Figure 6).

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PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 17 OF 29

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PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 18 OF 29

•8. Start the WHFocus program on the laptop.

•9. Click the AutoFocus Button to display the AutoFocus window.

•10. Click the Unlock button.

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PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 21 OF 29

•28. Connect the scanner to the laptop as shown in Figure 11.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 22 OF 29

The lists can be edited from the Tools menu item.

•31. Click the Scanner button.

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 23 OF 29

PRESS MORE TO DISPLAY

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If there was an error in processing the data, Measurement Error will be

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 27 OF 29

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 28 OF 29

If there is slight banding visible, you may be able to correct it by slightly

PROPRIETARY AND CONFIDENTIAL MKT-0505-AI REV 00 PAGE 29 OF 29

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