System 3 Service Bulletin 001

001: Lettering, Centering and Alignment for System 3 Machines.

002: Setting Ball Nut Preload on System 2 & System 3 Machines.

003: Setting System 3 Printwheel Belt Tension.

004: Pre-load Adjustment for System 3 Spindle Bearings.

005: Diagnosing System 3 Machine Problems.

006: Setting up the Cloth Feeder.

007: System 3 Printwheel Drive Sheave Positioning.

008: Setting Auxillary Sensors on the System.

009: Spindle bearing lubrication for System 2 & System 3.

010: Setting Wheel Tilt Positions on System 3.

011: System 3 Printwheel and Font Table Selection.

012: "Over Travel" Theory and Use.

Flesher: Technical Support System 3 Service Bulletin 001: Lettering, Centering and Alignment for SYSTEM 3 Machines SYSTEM 3 machines must be set up to match line spacing, line position and centering as required by the user. The procedure is described below. Unless special circumstances exist, the following parameters which are located in the file S3CONFIG.CFG should be set as shown below. These parameters are the defaults, and should have been set to the following values when the machine was initially installed. LINESPACEUNITS = 10 H_BASESLOT = 0 SLOTINC = 1 H_ABSOLUTESLOTS = YES V_BASESLOT = 0VERTINC = 1 V_ABSOLUTESLOTS = YES CHECKVERTICALRANGE = NO SETTING HORIZONTAL LINE SPACING Determine whether the horizontal slot numbering is to be ascending or descending. Descending slot numbers have largest number at the top of the spine and descending at the bottom of the spine. Set H_SLOTSEQUENCE as required. Example: H_SLOTSEQUENCE = DESCENDING Determine the horizontal line spacing required. Horizontal line spacing is the distance from the base line of one line to the base line of the following line. Determine this distance in ten thousandths of an inch; i.e. 3/8 inch equals .3750 inch equals 3750 ten thousandths of an inch. Set H_SLOTSCALE and HORIZONTALINC parameters to the required spacing. Example: H_SLOTSCALE = 3750, HORIZONTALINC = 3750. If fine adjustments need to be made, stamp test titles and adjust this parameter using the SHIFT-F5 key to access machine parameters. SETTING HORIZONTAL LINE POSITIONS This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System 3 machine. Prepare a test title with horizontal text on lines 5, 10, 15, 20, 25, and 30. Place a piece of cloth in the cloth feeder and use ALT-F4 to initiate the automatic load and stamp sequence. Examine the resulting lettered cloth for proper line positioning. If the base line of the lettering is not in the proper position, use SHIFT-F5 to access the machine parameters and change the HORIZONTALBASE parameter to adjust the relative position of the base lines. To raise the base line, increase HORIZONTALBASE and repeat the test. CENTERING HORIZONTAL TITLES ON THE CLOTH This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System3 machine. Prepare a test title with a single upper case "I" on line 1. Place a piece of cloth in the cloth feeder and use ALT-F4 to initiate the automatic load and stamp sequence. Examine the resulting lettered cloth for proper centering of the "I". If the character is not centered, use SHIFT-F5 to access the machine parameters and change the VERTICALBASE parameter to adjust the relative centering of the character. To move the character to the left, decrease VERTICALBASE and repeat the test. SETTING VERTICAL LINE SPACING Determine whether the vertical slot numbering is to be ascending or descending. Vertical line slot numbering is usually the same as for horizontal lines. Set V_SLOTSEQUENCE parameter as required. Example: V_SLOTSEQUENCE = DESCENDING Determine the vertical line spacing required. Vertical line spacing is the distance between the base line of one line and the base line of the following line in a multiple line vertical title. (In single line vertical titles, it has no effect.) Determine this distance in ten thousandths of an inch; i.e. 1/4 inch equals .250 inch which is 2500 ten thousandths of an inch. Set V_SLOTSCALE and VERTICALINC parameters to the required spacing. Example: V_SLOTSCALE = 2500, VERTICALINC = 2000. If fine adjustments need to be made stamp test titles and adjust this parameter using the SHIFT-F5 key to access machine parameters. SETTING VERTICAL LINE STARTING POSITIONS This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System 3 machine and horizontal line spacing and line positions have been set. Vertical title starting positions are set by the line numbers entered in the title. These line numbers correspond to line numbers for horizontal lines and may not be exactly correct for the start of a vertical line. The start of a vertical title may be adjusted by the parameter V_TEXT_ADJUST located in the S3CONFIG.CFG file. Normally this parameter is zero. Change it (either positive or negative) to shift the start position of vertical lines. CENTERING VERTICAL TITLES ON THE SPINE This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System3 machine and after completing the procedure for centering horizontal titles on the cloth. Centering of vertical titles on the spine is affected by the height of the characters being used. If line centering is calculated relative to a 18 point font, a 12 point vertical title will appear to be offset on the spine toward the bottom of the line while a 24 point title will appear to be offset toward the top of the line. To compensate for this, each font header in the WHEEL file has an OFFSET parameter. Adjust this offset parameter for each font to center each font. Example: "OFFSET -25". Stamp a single line title for each font to test entering. CENTERING TITLES ON THE FRONT COVER This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System3 machine and after completing all procedures for placement of horizontal titles. Front cover title placement is selected by the use of FC, FL, or FR justification codes. Regardless of which front cover title justification code is used, the center of the longest line of the title will be located at the reference according to the following formula: Reference = 1/2 SPINE + HINGESIZE + 1/2 BOARD + FX_ADJUST Where SPINE is the spine width entered in the title record, BOARD is the board width entered in the title record and HINGESIZE is a parameter in STAMPER.CFG file and FX_ADJUST is a parameter in the S3CONFIG.CFG file. HINGESIZE should already have been set to the nominal hinge allowance required for the of the cases. HINGESIZE is specified in thousandths of an inch, thus 3/8ths of an inch is 375. Example: HINGESIZE = 375. FX_ADJUST parameter is initially set to zero, but is used as a "tweaking" adjustment for placing the title in the center of the front cover. Examine several cases after they have been constructed to determine whether FX_ADJUST needs to be changed. A positive number for FX_ADJUST moves the placement more toward the right side of the book while a negative number moves it nearer the left side. SETTING THE POSITION OF CALL NUMBERS ON THE LEFT FRONT COVER This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System3 machine and after completing all procedures for placement of horizontal titles. Front cover call number placement is selected by the use of FC, FL, or FR justification codes. Regardless of which front cover call number justification code is used, the left side of the longest line of the call number will be located at the reference according to the following formula: Reference = 1/2 SPINE + HINGESIZE + COVERGAP Where SPINE is the spine width entered in the title record, HINGESIZE and COVERGAP are parameters in the STAMPER.CFG file. HINGESIZE should already have been set to the nominal hinge allowance required for the construction of the cases. HINGESIZE is specified in thousandths of an inch, thus 3/8ths of an inch is 375. Example: HINGESIZE = 375 COVERGAP parameter is initially set to the desired distance from the left edge of the board to the left side of the longest line of the call number. Examine several cases after they have been constructed to determine whether COVERGAP needs to be adjusted. A positive number for COVERGAP moves the placement more toward the center of the book while a negative number moves it nearer the spine. SETTING THE POSITION OF CALL NUMBERS ON THE RIGHT FRONT COVER This procedure should be carried out only after the cloth feeder has been set up to feed the cloth properly into the cloth clamps of the System3 machine and after completing all procedures for placement of horizontal titles and after completing the procedure for setting the position of call numbers on the left front cover. Front cover call number (right edge) placement is selected by the NC, NL, or NR justification codes. Regardless of which front cover call number justification code is used, the right side of the longest line of the call number will be located at the reference according to the following formula: Reference = 1/2 SPINE + BOARD + HINGESIZE - COVERGAP + NX_ADJUST Where SPINE is the spine width entered in the title record, BOARD is the board width entered in the title record, HINGESIZE and COVERGAP are parameters in the STAMPER.CFG file, and FX_ADJUST is a parameter in the S3CONFIG.CFG file. HINGESIZE should already have been set to the nominal hinge allowance required for the construction of the cases. HINGESIZE is specified in thousandths of an inch, thus 3/8ths of an inch is 375. Example: HINGESIZE = 375 COVERGAP parameter should have already been set in the procedure for setting the position of call numbers on the left front cover. NX_ADJUST parameter is initially set to zero, but is used as a "tweaking" adjustment for placing the call numbers the desired distance from the right edge of the board. Examine several cases after they have been constructed to determine whether NX_ADJUST needs to be changed. A positive number for NX_ADJUST moves the placement more toward the right edge of the book while a negative number moves it nearer the center. Examine several cases after they have been constructed to determine whether NX_ADJUST needs to be changed. A positive number for NX_ADJUST moves the placement more toward the center of the book while a negative number moves it nearer the spine.