MAKO 2 CTP, MAKO 2x CTP, MAKO 4 CTP, MAKO 4x CTP, and MAKO NEWS CTP
AO111334 Revision 2
Operator Guide
MAKO 2 CTP, MAKO 2x CTP, MAKO 4 CTP, MAKO 4x CTP and MAKO NEWS CTP
copyright ECRM Incorporated 2008 Additional copies of this guide may be obtained by writing or calling:
Table of Contents
Table of Contents iii Preface v
Scope of this Guide v Organization v Terms and Conventions vi
System Overview 1
The MAKO CTP Series 1 Functional Overview 1 System Components 3 Main Parts of the Platesetter 5 System Requirements 8 Laser Safety 9 Regulatory Information 10
System Operation 13
Introduction 13 Starting Up the System 13 Shutting Down the System 14 Using the Control Panel 14 Operator Menus 16 User Preference Menu 17 User Maintenance Menu 22 Test Patterns Menu 24 Equipment Configuration Displays 29 Display Messages 30 Running a Step Wedge Test 31
Media Handling 37
Media Specifications 37 Safelight Requirement 37 Installing and Removing the Pin Bar 38 Loading Media 42
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Preface
Scope of this Guide
This guide explains how to operate and maintain MAKO CTP series platesetters. The guide describes all aspects of operating a system. All platesetters in the series use a Class Four laser. This guide contains important safety information and regulatory information about the laser. You should read this information thoroughly before operating the system or performing the procedures described in this guide. This guide assumes the system is already properly installed and plugged into the AC mains, and that the system has been calibrated and tested for proper operation and acceptable output.
Organization
Chapter 1: System Overview
This chapter presents a system overview. It includes system operating requirements and information about laser safety.
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System Overview
The MAKO CTP Series
Functional Overview
All the systems use a violet laser. MAKO 2, MAKO 2x, MAKO 4, and MAKO 4x are for commercial printing environments, whereas the MAKO NEWS is for newspaper publishing. All the systems perform the same basic functions and are operated the same way. The main differences between the systems include the imaging resolutions and media sizes they support, and the type of pinch mechanism they use (see the feature comparison tables on the next page).
Note: This manual makes no distinction between systems except where necessary. In the presentation that follows, except where otherwise noted, all references to the platesetter or the system pertain to any system in the series.
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RESOLUTIONS
(DOTS PER INCH)
1200
1270
1500
1800
2032 2400
2540
3048
3556
SYSTEM
Maximum Edge Register
MAKO 2 CTP MAKO 2 CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS CTP
Notes:
560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 635 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)
1. (W) and (L) designate the width and length of the plate in millimeters (mm). 2. Edge Register: maximum plate size (edge to edge imaging) using an edge-register pin bar. 3. Notch Register: maximum plate size (edge to edge imaging) using an notch-register pin bar. The notch register plate size requires a minimum 12 mm notch depth, except System 4x, which requires a minimum 11 mm notch depth. 4. Minimum Edge Register: Minimum plate size. The minimum plate size of 252 mm (L) requires a custom pin bar on all 4-page machines.
SYSTEM
Manual
MAKO 2 CTP MAKO 2X CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS CTP
PINCH MECHANISM
The operator uses a pinch bar to manually open and close the pinch rollers.
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System Components
A complete system includes a control workstation, CtServer software, a power conditioner, and a platesetter.
CONTROL WORKSTATION*
IMAGING UNIT
CT SERVER SOFTWARE
CONTROL PANEL TRANSPORT UNIT
POWER CONDITIONER
REGISTRATION PIN BARS
PLATESETTER
Platesetter
The platesetter images and outputs plates.
Workstation
The workstation connects directly to the platesetter and runs the CtServer software. Operating instructions for the workstation are provided with the workstation. The operator makes frequent use of the workstation when running the platesetter. For that reason, the workstation should be set up next to the platesetter.
CtServer Software
CtServer is used to send jobs to the platesetter. It is also used to define the plate and pin bar requirements for jobs and communicate that information to the platesetter, which displays the information on the control panel LCD.
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Some operating parameters that can be set in CtServer can also be set at the control panel. For these parameters, the CtServer setting always overrides the control-panel setting. The use and operation of CtServer is documented in the CtServer Users Guide, which is delivered as a PDF on the CtServer CD.
Power Conditioner
The power conditioner shields the system from as ac power spikes, voltage drops, and other electrical power disturbances. The platesetter, the control workstation, and the control workstation monitor must all be plugged into the power conditioner, which in turn must be plugged into a grounded ac power outlet.
Platesetter System
POWER CONDITIONER
AC INLET AC OUTLETS
AC MAINS
AC Power
AC Power
AC Power AC Power
AC INLET
RS-232* USB
AC INLET
AC INLET
PROCESSOR
PLATESETTER
Plate Line IF
WORKSTATION
(with CtServer)
Monitor
MONITOR
CONTROL PANEL PIN BAR POWER SWITCH MEDIA TRANSPORT OUTPUT SENSOR
INPUT SENSOR
(NOT PRESENT IN MAKO 4 AND MAKO NEWS)
BACK
FRONT
Power Cord
The power cord plugs into a receptacle located just below the power switch.
Pin Bar
The pin bar is used for plate registration. There are two types of pin bars: press notch registered and edge registered.
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Two pin bars come with the system as standard equipment. Additional pin bars can be ordered as an option. Exposing sets of plates with different registration notch requirements is easily accomplished by changing the pin bar.
Control Panel
The control panel allows you to interact with the platesetter. Commands and options are controlled through this device.
Input Tray
The input tray is used to position the plate for exposure. The plate is placed on the input tray and gently slid to engage the registration pins. A groove is provided in the surface of the input tray to provide a convenient place to push the plate forward. A plate cannot be loaded until the previous plate has been completed.
On MAKO 2 and MAKO 4 platesetters, a pinch roller bar is used to open and close the pinch rollers. These high precision rollers control the movement of plate during exposing. The pinch roller bar is raised (pinch rollers open) to load a plate and lowered (pinch rollers closed) to expose a plate. Never raise the pinch roller bar while a plate is being exposed! Doing so will cause the plate to jam inside the platesetter if you are using an edge-registered pin bar.
Note: The pinch roller bar must be up during the initialization process after a power on.
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PINCH ROLLERS
Fan Filters
The platesetter uses 2 fan filters. The filters slide into slots on either side of the unit. See Figure 1-3 on Page 5.
Note: To avoid damaging the filters, when lifting the platesetter off the pedestal, do not grasp the platesetter at points where the filters are located.
The Pedestal
The pedestal is a specially designed base for the platesetter.
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System Requirements
Safelighting
The platesetter is designed to be operated in a safelight environment.
Environmental Requirements
TemperatureHumidity 62 - 86 degrees F (17 - 30 degrees C) 45 - 65%, non-condensing.
Note: Operating the system outside of the ranges specified above may affect performance.
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Laser Safety
Laser Product Classification
The system is classified as a Class one (I) laser product. This classification means the operator is not exposed to hazardous laser light during operation and maintenance. The laser in the system is a Class Four (IV) device which emits visible laser light that is considered hazardous by FDA published limits.
IMPORTANT WARNING
Use of controls or adjustments or performance of procedures other than those specified in this guide may result in hazardous laser light exposure.
MEDIA SENSITIVITY
405 nm VISIBLE
Figure 1-5 Media Sensitivity Label
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Regulatory Information
Electromagnetic Emissions
DOC - Canada The Canadian Department of Communications requires compliance with the Radio Interference Regulations, ICES -003. This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. EMC Directive - Europe Complies with EN 55011: 1998 This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. FCC - USA The standards for electromagnetic emissions are Part 15, Subpart J of the FCC rules. The system was tested to Class A limits. The following statements are required by the FCC: Changes or modifications to this unit not expressly approved by the party responsible for compliance could void your authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction guide, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to
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correct the interference at his or her own expense. Compliance with applicable regulations depends on the use of shielded cables. The user is responsible for procuring the appropriate cables.
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System Operation
Introduction
The same basic operating procedures apply to all models in the series. Except where otherwise noted, all the information that follows pertains to every model in the series.
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LCD
PREV
NEXT
OK
Accessing Menus
Access menus from the system control panel. Enter the menu subsystem by pressing MENU from the ONLINE state.
MENU
SELECT
CANCEL
KEYPAD
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Keys
PREVIOUS
PREVIOUS - Moves you backward within the menu or moves the cursor backward within the current menu item. ENTER - Enter or exit the menu sub-system by pressing MENU from the ONLINE state. NEXT - Moves you forward within the menu or moves the cursor forward within the current menu item. START - Starts exposing the loaded plate. Also, from anywhere in a numeric field, causes the next menu item to be displayed. In the last item of a menu, causes a return to the first item of the menu. SELECT -Increments the numeric digit under which the cursor is positioned or scrolls through the options available for the current menu item CANCEL - Cancels a pending load plate request, but does not stop a job that is in progress. STOP - The Emergency stop button. This button will stop all moving parts of the platesetter.
MENU
NEXT
OK
SELECT
CANCEL
LEDs
EXPOSE
.Green LED that indicates the plate is being exposed when it is flashing. Additionally, indicates registration pin contact when loading a plate. Yellow LED indicates there is a condition that requires operator attention. The LCD display indicates what needs to be done. Red LED that indicates a platesetter error condition. The LCD display indicates what the error is.
ATTENTION
ERROR
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Operator Menus
There are three operator menus:
User Preference Menu (see page 17). User Maintenance Menu (see page 22). Test Pattern Menu (see page 24).
Menu Selection
Follow these steps to set the parameters in any menu.
Step 1. Press MENU to enter the user menu system. Step 2. Press SELECT until the sub-menu you want displays on the LCD. Step 3. Press NEXT to enter the selected sub-menu. Step 4. Set the parameter to what you want. Step 5. Press SELECT to change the value. Step 6. Press NEXT to go to the next parameter until you have completed your selections. Step 7. Repeat steps 4 and 5 until all changes are made. Step 8. Press MENU to exit the user menu system.
ONLINE
MENU
USER PREFERENCES
NEXT
SELECT
SELECT
SELECT
TEST PATTERNS
NEXT
The selected units of measure apply to all numeric measurement values in various menus. AUDIO ALERTS OPTIONS ENABLED or DISABLED
This menu item allows you to disable or to enable the audible alarms for the following conditions: Error conditions, Power-up, Image complete HORIZONTAL MAGNIFICATION LIMITS 85.00% to 110.00%
Sets the size of the image in the horizontal direction from 85% to 110% of nominal.
Note: The CtServer magnification setting overrides the control panel setting.
Sets the size of the image in the vertical direction from 85% to 110% of nominal.
Note: The CtServer magnification setting overrides the control panel setting.
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USER PREFERENCES
NEXT
SELECT
USER MAINTENANCE
SELECT
SELECT
UNITS OF MEASURE
NEXT
PROCESSOR SPEED
NEXT
AUDIO ALERTS
NEXT
HORIZONTAL MAGNIFICATION
NEXT
VERTICAL MAGNIFICATION
NEXT
INDEXING IS ENABLED
NEXT
IMAGE OFFSET
NEXT
ONLINE
The image may be shifted to the left with a negative (-) value, or to the right with a positive (+) positive value. ONLY 1 PIN BAR IN USE OPTIONS: YES or NO
YES prevents the system from displaying a prompt to verify that the correct pin bar is installed whenever you open an autoloader cover. NO permits the system to display the prompt. IGNORE LASER TEMPERATURE ERRORS OPTIONS YES or NO
If the laser exceeds its target operating temperature an error will be reported. It is recommended that this problem be fixed. However, if critical jobs need to be completed, it is possible to operate the laser at a higher temperature. This operation is enabled by ignoring the laser temperature errors.
Note: Operating the laser at a higher temperature shortens the life of the laser.
If this option is set YES, an operator can begin imaging another plate while the previous plate is feeding into the processor. PROCESSOR SPEED LIMITS 9.5 per minute to 77.9 (241 mm/min. to 1980 mm)
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USE TRANSPORT AS AN OUTPUT TRAY OPTIONS: YES or NO YES disables the media transport conveyor and effectively makes the transport function as an output tray. NO (the default setting) enables the conveyor to operate and transport plates to the processor. USE THE PLATELINE INTERFACE OPTIONS: YES or NO
YES enables the plateline interface to halt the platesetter when another device in the plate line is not ready to perform its function. NO causes the platesetter to ignore the plateline interface. This feature should be set to NO if a plateline interface is not being used. REGISTRATION DELAY BEFORE PINCHING PLATE LIMITS 0.10 seconds to 5.00 seconds Sets the length of time the system waits to close the pinch rollers after the plate is registered. The default setting is 0.50 seconds. AUTOMATICALLY BEGIN IMAGING AFTER PINCHING OPTIONS YES or NO YES enables the platesetter to automatically image the plate immediately after the pinch rollers close. NO disables the platesetter from doing so. When NO is selected, you must manually initiate imaging by pressing the OK button.
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INDEXING IS ENABLED OPTIONS YES or NO When YES is selected, the platesetter indexes the input rollers before starting each new image. When NO is selected, the platesetter does not index the rollers. This improves throughput, but may impact repaeatability and/ or registration.
Note: This feature is useful in systems that have an autoloader. If you have a manual load system, leave the feature set for the default (YES) setting.
PRE-IMAGE SETTLE TIME LIMITS 0.50 to 2.50 seconds The default setting is 2.00 seconds. Reducing the settle time improves throughput, but may decrease image quality at the leading edge of the plate.
Note: This feature is useful in systems that have an autoloader. If you have a manual load system, leave the feature set for the default (2.00) setting.
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where nnnnnn is the part number of the controller board, JP0020 n.n is the part number and revision level of the controller software, and JA1135 n is the part number and revision level of the controller firmware. RUN TRANSPORT This user maintenance option will run the media transport until the STOP button is pressed. This function is used to clean the transport. RUN MEDIA ROLLERS This option runs the media rollers until the STOP button is pressed. This function is used to clean the rollers. DISPLAY ERROR LOG This user maintenance option presents system faults (up to a maximum of 20 faults) in chronological order. TIME is the elapsed time since the latest power on. SESSION # is the total number of times the system has been turned on. DEVICE NAME identifies the system component that failed. ERROR is an indication of the nature of the fault. DISPLAY LASER LOG This option presents status information about the system laser. The information is useful to service personnel, who sometimes request the information over the phone during service calls.
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USER PREFERENCES
SELECT
USER MAINTENANCE
NEXT
SELECT
SELECT
NEXT
PROGRAM VERSIONS
SELECT
NEXT
RUN TRANSPORT
SELECT
NEXT
NEXT
EXPOSE ATTENTION
ERROR
NEXT
PREV
NEXT
OK
MENU
SELECT
CANCEL
ONLINE
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This option moves the system in and out of test pattern mode. TEST PATTERN TYPE OPTIONS List of Test Patterns
Test Patterns are described fully in the system Reference guide and are for the use of qualified technicians only. NUMBER OF PLATES OPTIONS 1 to 60 plates
Sets the number of plates that will be imaged in the test session. REVERSE IMAGE POLARITY OPTIONS YES or NO
Reverses the test pattern images. YES will expose the background of the plate. NO will expose the image area. BAR WIDTH OPTIONS 1 to 999999 Pixels
Specifies the width of the lines in the Bar Test Patterns. BAR SPACING OPTIONS 1 to 999999 Pixels
This parameter specifies the width of the spaces between the lines in the Bar Test Patterns.
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ONLINE
MENU
USER PREFERENCES
SELECT
USER MAINTENANCE
SELECT
SELECT
NEXT
SELECT
ENABLE
SELECT
NEXT
DISABLE
NUMBER OF PLATES
NEXT
NEXT
NEXT
EXPOSURE LEVEL
NEXT
PLATE WIDTH
NEXT
HORIZONTAL MAGNIFICATION
NEXT
NEXT
PLATE LENGTH
NEXT
VERTICAL MAGNIFICATION
OK NEXT
ONLINE
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NOTCH DEPTH
25
This parameter specifies the length of the test pattern to be recorded. IMAGE OFFSET (VERTICAL) OPTIONS 0.0000 to 39.330 or 0 mm to 999 mm
This parameter specifies the distance from the leading edge of the plate to the first line of the image. HORIZONTAL RESOLUTION By picking any of the optional values, you set the horizontal resolution to that value. Horizontal Resolution is not displayed if a GRID test pattern is selected. OPTIONS 1200, 1270, 1800, 2400, 2540, 3048 and 3556 (dpi) 47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0 (dpmm)
Note: Resolution is model dependent. Your options may differ from those listed above. See Table 1 - 1, FEATURE COMPARISONS, on page 2.
VERTICAL RESOLUTION OPTIONS 1200, 1270, 1800, 2400, 2540, 3048 and 3556 (dpi) 47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0 (dpmm) By picking any of the optional values, you set the vertical resolution to that value. Vertical Resolution is not displayed if a GRID test pattern is selected.
Note: Resolution is model dependent. Your options may differ from those listed above. See Table 1 - 1, FEATURE COMPARISONS, on page 2.
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By picking a value, you set the plate width for test patterns. Plate width is model dependent. Your options may differ from those listed above. See Table 1 - 1, Feature Comparison, MAKO System 4 and 4x Platesetters, on page 2.
Plate width is model dependent. Your options may differ from those listed above. See Table 1 - 1, FEATURE COMPARISONS, on page 2
By picking a value, you set the plate length for test patterns. Plate length is model dependent. Your options may differ from those listed above. See Table 1 - 1, Feature Comparison, MAKO System 4 and 4x Platesetters, on page 2.
Plate length is model dependent. Your options may differ from those listed above. See Table 1 - 1, Feature Comparison, MAKO System 4 and 4x Platesetters, on page 2
By picking a selection, you set the alignment to be used for test patterns. Punched plates are generally notch registered as opposed to edge registered.
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By picking a value, you set the notch depth for test patterns. DISTANCE FROM NOTCH TO LEADING EDGE OPTIONS 1.665 to 37.873 or 42.3 mm to 961.9 mm
This options specifies the distance from the leading edge of the plate to the center of the notch that is closest to the leading edge. This parameter is only for notch-registered plates. EXPOSURE LEVEL LIMITS 000 to 255
This menu entry sets the exposure level at the media. The higher the number, the higher the exposure. HORIZONTAL MAGNIFICATION LIMITS 85.00% to 110.00%
Sets the size of the image in the horizontal direction from 85% to 110% of nominal. VERTICAL MAGNIFICATION LIMITS 85.00% to 110.00%
Sets the size of the image in the vertical direction from 85% to 110% of nominal.
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ONLINE
SELECT
SYSTEM CONFIGURATION
DISPLAY 2
SELECT
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Display Messages
During operation, the system displays status messages about the condition of the system and the progress of any jobs in process. The status messages appear on the control display. - The system is starting the spinner and moving the plate to the recording start position.
PREPARING TO EXPOSE EXPOSING IMAGE
EJECTING PLATE -
Exposing is complete and the plate is being ejected onto the plate transport.
- Plate has been ejected from the rollers and is moving to the processor.
MOVING TO PROCESSOR FEEDING PROCESSOR EJECTING PLATE ONLINE
- Plate is on the transport and the leading edge of the plate is moving into the processor. - Exposing is complete and the plate is being ejected onto the plate transport. - The normal operating mode for the system
STARTING SPINNER TEST PATTERNS
- This message is accompanied by a progress bar when preparing to start an image and the spinner motor is - Test Patterns mode has been selected in the Test Patterns Menu and the system is ready to produce a test pattern. This mode of operation should be used by qualified service technicians only. The system is performing initialization functions prior to going online.
INITIALIZING -
Note: On a MAKO System 4, if the Pinch Roller bar is down, you will be prompted to raise it during initialization.
The system is waiting for the laser to reach its operating temperature.
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The figure below shows a step-wedge test strip. It happens to have 15 steps. Some test strips have fewer than 15 steps, whereas others have more. On any given test strip, the first step is virtually clear, the last step is virtually black, and steps in between are of varying density, with each step being darker than the preceding (lower-numbered) step.
10 12 13 14 14 15 15 11 1 2 3 4 5 6 7 8 9
10
12
Figure 2-7 Example Step-Wedge Test Strip When the test strip is taped over the plate, clear step 1 allows virtually all of the energy in the imaging beam to hit the plate, step 2 slightly less energy, step 3 still less energy, etc.
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On a typical test plate, the lower-numbered wedge steps are completely imaged (very dark), the higher-numbered steps are barely imaged (very light/clear), and one or two transition steps between the dark and light areas are partially imaged.
5 10 12 13 14 14 15 15 11 5 7 1 2 3 4 6 8 9
10
12
Figure 2-8 Typical Step-Wedge Test Plate Image The distribution of dark steps, transition steps, and light step varies depending on the platesetters exposure setting, the plate type being used, and the state of the processor chemistry.
Note: ECRM recommends using a Fuji 15-step T step wedge test strip (ECRM PH0388) on Fuji plates, and a Stouffer 21step wedge (ECRM PH0389) on all other plates.
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11
Step 2. Center the test strip on the plate 6 inches (15.2 cm) back from the leading edge, as shown below. Be sure to use two pieces of tape. Make sure the emulsion side of the step wedge faces the emulsion side of the plate.
TAPE
TAPE
Step 8. Set Plate Thickness to the plate thickness being used. Step 9. Set Plate Width to the plate width being used. Step 10. Set Plate Length to the plate length being used. Step 11. Set Magnification Horizontal to the magnification being used (normally 100%). Step 12. Set Magnification Vertical to the magnification being used (normally 100%). Step 13. Select MENU. Step 14. Press the SELECT key to begin exposing the test plate. The system exposes 100% of the first 8 inches of the plate at the exposure setting selected. After exposure, the plate moves onto the transport belt and advances until the leading edge of the plate is detected by the transport exit sensor. The transport then stops, the warning light on the top cover flashes, and a prompt to open the transport cover and remove the step wedge displays on the control panel.
Note: Note: In step wedge test pattern mode, the machine will not beep or report cover interlock open messages.
Step 15. On the front panel, press OK. The transport feeds the plate into the processor. Step 16. Process the plate. Step 17. Evaluate the output.
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3 4 5 6
3 4 5 6
No brush marks appear. Solid Step # may be visible. Approximately 50% Tail* exposure of area. Brush marks visible. Some minimal ghosting Clear may appear.
Step 3. Refer to the * Sometimes called Ghost or Scum, Tail steps table below for exhibit only partial exposure of the plate. exposure step wedge values for Figure 2-10 several popular plate types. The values shown in the table are for an ideal testing environment. Plate lot, plate age, processing conditions, and processor chemistry can have a dramatic effect on step wedge results. Always check these factors if your step wedge test results significantly differ from those shown in the table.
Plate Manufacturer
Fuji Lastra KPG Agfa
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Step 4. Example Figure 2-11 below shows how Fuji LP-NV test plates look for different exposure settings. Use the figure as a guide for evaluating your test output. If necessary, increase/decrease the platesetters exposure setting and then run another wedge test.
10 12 13 14 14 14 14 14 14 15 15 15 15 15 15 11 1 2 3 4 5 6 7 8 9
10
12 12 12 12 12
10
B
10 EXPOSURE SETTING TOO HIGH 13 13 13 11 1 2 3 4 5 6 7 8 9
10
10
Figure 2-11
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11
C
1 2 3 4 5 6 7 8 9
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11
13
11
A
1 2 3 4 5 6 7 8 9
Media Handling
Media Specifications
L = Length Configurations
Prepunched Press Grooves or Edge Register
3
W = Width
Media Thicknesses
5.5 mil (0.14mm) 6 mil (0.15 mm) 8 mil (0.20mm) 10 mil (0.25mm) 12 mil (0.30mm)
MEDIA
Plate Sizes
SYSTEM
Maximum Edge Register
MAKO 2 CTP MAKO 2X CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS CTP
560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 635 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)
560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 660 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)
228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L)
Safelight Requirement
The platesetter is designed to be operated in a safelight environment. All media handling must be done under safelight conditions. Safe working time varies with manufacturer. See the plate manufacturers specification for safelight recommendations.
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The pin bar is located in a channel on the left side of the input tray. Note: MAKO 2x, MAKO 4x and MAKO NEWS models do not have a pinch roller bar.
PINCH ROLLER BAR
CHANNEL
INPUT TRAY
PIN BAR
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Figure 3-3 shows the main parts of the pin bar. The alignment pin helps keep the pin bar in proper alignment with the rest of the media handling system. The latch at the other end of the pin bar locks the bar in place in the channel.
REGISTRATION PINS
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FRONT OF CHANNEL
HOOK
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Step 7. Firmly press the center of the pin bar down to insure it is properly seated.
ALIGNMENT PIN HOOK
PIN BAR
CHANNEL
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Loading Media
CtServer will request a pin bar and plate to be loaded, and the platesetter will prompt you to load the plate. One of the following prompts appears on the control panel LCD:
LOAD A PLATE <plate name> <bar name>
This message indicates that the next plate to be imaged is the same as the preceding plate. It is a prompt for you to load the same kind of plate that was just imaged.
LOAD A NEW PLATE <plate name> <bar name>
This message indicates that the next plate to be imaged is different than previous plate, but that it uses the same pin bar. It is a prompt for you to load the new (different) type plate.
VERIFY BAR AND LOAD <plate name> <bar name>
The meaning of this message depends on when it appears during the CtServer (host computer) session. When the session is first opened, it is a prompt for you to ensure that the correct pin bar is installed before loading the first plate, and then to load the plate. Subsequently in the session, the message indicates that the next plate to be imaged is different than the preceding plate AND requires a different pin bar. Thus, it is a prompt for you to change the pin bar and load the new (different) plate. The technique used for loading plates is a key in achieving good plate registration. Always handle and position the plate gently and carefully. Thin plates are especially susceptible to dings and dents.
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BACK
PEDESTAL
FRONT
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Step 2. Raise the pinch roller bar to open the pinch rollers. Be sure the pinch roller is fully raised. If it is not, the green Expose LED on the control panel will not light.
Step 3. Verify the requested pin bar is loaded. If it is not, change the pin bar. Step 4. Place the requested plate on the input tray. Step 5. Push the plate to the left (Figure 3-7, A) so that the edge of the plate contacts the registration pins in the pin bar.
PINCH ROLLERS
A B
Figure 3-7 Loading Edge-registered Plates
Step 6. Push the plate forward into the platesetter (Figure 3-7, B) until you feel it make contact with a third registration pin that is inside the platesetter.
44 AG111334 Rev. 2
Step 7. Gently adjust the position of the plate as needed to get the green Expose LED to come on and stay on. This shows the plate is maintaining contact with all 3 registration pins (the 2 on the pin bar, plus the 1 inside the platesetter). If the LED goes out, you have lost pin contact. Move the plate out and to the right slightly, and then back in and to the left until the green LED stays on. Be careful to not apply so much pressure to the plate that the registration pins dent the plate. Use one finger/thumb to apply minimal pressure to the center of the plate. Note: If the green LED is not staying illuminated, the pin bar may not be fully seated. Remove and reinstall the pin bar, following the instructions above. Step 8. Holding the plate in position, lower the pinch roller bar. The green light will remain on if pin contact has been maintained and the platesetter will prompt for the OK button to be pressed to start imaging.
GREEN LED
EXPOSE
ATTENTION ERROR
PREV
NEXT
OK
OK
MENU
SELECT
CANCEL
Figure 3-8
Note: If the green LED does not stay illuminated, open the pinch roller bar and go back to Step 5. Step 9. Press the OK button. Imaging begins.
CAUTION - Never raise the pinch roller bar while a plate is being exposed. Doing so will cause the plate to jam inside the platesetter. For details, refer to Clearing Misfeeds, Manual Pinch Mechanism on page 58.
Step 10. After the plate is imaged, it is automatically transported from the platesetter to the on-line processor via the media transport.
AG111334 Rev. 2
45
Step 3. Verify the requested pin bar is loaded. If it is not, change the pin bar. Step 4. Place the requested plate on the input tray. Step 5. Position the plate so that both notches in the plate fully engage the two registration pins on the pin bar (see Figure 3-9 on Page 47).
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AG111334 Rev. 2
NOTCH
Step 7. Holding the plate in position, lower the pinch roller bar. The green light will remain on if pin contact has been maintained and the platesetter will prompt for the OK button to be pressed to start imaging. Note: If the green LED does not stay illuminated, open the pinch roller bar and go back to Step 5. Step 8. Press the OK button. The plate will be backed up to properly position the leading edge for exposing. Step 9. After the plate is imaged, it will automatically be transported out of the platesetter and into the on-line processor.
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AG111334 Rev. 2
Note: For instructions for loading an edge-registered plate in a system with a manually operated pinch mechanism, refer toLoading Edgeregistered Plates in a MAKO 2 or MAKO 4 on page 44.
A
PIN BAR EDGE OF PLATE
REGISTRATION PIN
PLATE
B
49
Step 5. Push the plate forward (B in Figure 3-10) until it comes into contact with a third registration pin that is inside the platesetter. Step 6. Gently adjust the position of the plate until the green Expose LED stops blinking and stays on steady. (Steady on indicates the plate is making contact with all the registration pins). Step 7. The platesetter automatically lowers the pinch rollers. Note: The platesetter will not lower the pinch rollers until electronics sensors report that the plate is making good contact with all the registration pins. If the pin bar isnt properly seated in its mount, the sensors may not operate correctly and the platesetter may not close the pinch rollers. If you load a plate that it is making good contact with the registration pins but the pinch rollers dont close, try re-seating the pin bar. After the pinch rollers close, the platesetter does either of the following, depending on the setting of the Automatically Begin Imaging After Pinching menu option:
See User Preferences Menu on page 13. for more about the Automatically Begin Imaging After Pinching menu option.
automatically begins imaging the plate, or displays a PRESS OK TO BEGIN prompt on the control panel display. Step 8. If the prompt appears, press the OK button. Step 9. After the plate is imaged, it is automatically transported to the online processor via the media transport.
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AG111334 Rev. 2
Loading Notch-registered Plates in a MAKO 2x, MAKO 4x, or MAKO NEWS System
Step 1. Face the input tray. Step 2. Verify the requested pin bar is loaded. If it is not, change the pin bar. Step 3. Place the requested plate on the input tray. Note: For instructions for loading a notch-registered plate in a system with a manually operated pinch mechanism, refer toLoading Notchregistered Plates in a MAKO 2 or MAKO 4 on page 46.
Step 4. Position the plate so that both notches in the plate fully engage the two registration pins on the pin bar (see Figure 3-11).
PINCH ROLLERS REGISTRATION PIN
NOTCH
Step 5. Gently adjust the position of the plate until the green Expose LED stops blinking and stays on steady. (Steady on indicates the plate is making contact with all the registration pins). Step 6. The platesetter automatically lowers the pinch rollers. Note: The platesetter will not lower the pinch rollers until electronics sensors report that the plate is making good contact with all the registration pins. If the pin bar isnt properly seated in its mount, the sensors may not operate correctly and the platesetter may not close the pinch rollers. If you load a plate that it is making good contact with the registration pins but the pinch rollers dont close, try re-seating the pin bar. After the pinch rollers close, the platesetter does either of the following, depending on the setting of the Automatically Begin Imaging After Pinching menu option:
See User Preferences Menu on page 13. for more about the Automatically Begin Imaging After Pinching menu option.
automatically begins imaging the plate, or displays a PRESS OK TO BEGIN prompt on the control panel display.
Step 7. If the prompt appears, press the OK button. Step 8. After the plate is imaged, it is automatically transported to the online processor via the media transport.
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AG111334 Rev. 2
General Maintenance
This chapter explains how to keep the system in clean, working order. Remember to shut the power off to the machine prior to performing any internal maintenance procedures. Use only the recommended cleaner. Make sure the cleaning supplies are free of lint and dirt.
AG111334 Rev.2
53
CONTROL PANEL PIN BAR POWER SWITCH MEDIA TRANSPORT OUTPUT SENSOR
INPUT SENSOR
(NOT PRESENT IN MAKO 2 AND MAKO 4)
INPUT TRAY
BACK
PEDESTAL
FRONT
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AG111334 Rev.2
The filters can become clogged with dust and other debris if it is not cleaned regularly. A clogged filter can result in the loss of internal pressure and increase the possibility of a system malfunction. Clean the filters whenever they show signs of contamination with dust or other debris Heres how to remove and replace a filter:
Step 1. Turn the power switch off. Step 2. From inside the pedestal, reach up and under the machine where the on/off switch is located. See Figure 4-3. Step 3. Place your fingers on the filter. It has a corrugated feel. Step 4. Gently push the filter toward the outside of the machine until the filter protrudes from the slot shown below.
Figure 4-2
ON/OFF SWITCH
FAN FILTER
SLOT
PEDESTAL
Step 5. Pull the filter out of its slot. Step 6. Wash the filter in mild, soapy water, rinse in clean water and dry. Step 7. Place the filter back into the slot. Step 8. Push the filter, from the outside, until it is completely in the machine. Step 9. From inside the pedestal, gently push the filter to the middle of the machine until it is fully seated in the holder. Step 10. Repeat steps 1 through 10 above for the other filter, which is located on the opposite side of the system.
56
AG111334 Rev.2
taminate the rollers. Step 7. If water fails to remove the gum, use ECRM PH0046 roller cleaner. (Do NOT use alcohol or a general purpose cleaner to clean the rollers.) Step 8. Exit the User Maintenance Menu.
HB2456), remove debris from the belt (see Figure 4-1). Step 3. Using a second lint-free cloth moistened with alcohol, rub down the belt.
Method 2 When an edge-registered pin bar is used, a third internal registration pin is activated. The location of this pin (which you can feel but not see when you load a plate) is shown below in Figure 44. The pin moves up into the media path when the pinch mechanism is raised, and it drops below the media path when the mechanism is lowered.
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AG111334 Rev.2
REGISTRATION PIN
PLATE
PIN BAR
NOTE The Internal Registration Pin goes up when the Pinch Roller Bar is raised and goes down when the Pinch Roller Bar is lowered.
REGISTRATION PIN
Figure 4-4 Internal Registration Pin During imaging, the registration pin is below the plates path of travel. If a misfeed or a power failure happens to occur and the plate gets hung up in the machine with a manual pinch mechanism, you are advised not to raise the pinch roller bar. Doing so will raise the registration pin. If the plate happens to be positioned over the registration pin (Figure 4-5 View B), when the pin comes up and it will bend or dent the plate.
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59
PLATE
PLATE
Figure 4-5 Plate Positions over the Registration Pin To insure against this happening, use the following procedure to remove the plate:
Step 1. Do not raise the pinch roller bar or power off the machine. Step 2. Use the control panel PREV and NEXT buttons as follows to extract the plate: Press the PREV button to effect a movement of the plate toward the front of the machine, and then press the button again to stop the movement. Press the NEXT button to effect a movement of the plate toward the back of the machine, and then press the button again to stop the movement.
Step 3. Exercise the PREV and NEXT buttons as required until the plate out all the way of the machine.
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AG111334 Rev.2
Step 4. Press the OK button. This turns off the blinking error light and clears the the error message from the display. Step 5. Resume normal operation.
LEVELING FEET
AG111334 Rev.2
61
place the system in its new location. Step 4. Turn all four levelling feet of the platesetter down until they just touch the floor. Step 5. Continue to turn leveling feet until the system is level, front to back and side to side.
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AG111334 Rev.2
A AUDIO ALERTS menu item 17 AUTOMATICALLY BEGIN IMAGING AFTER PINCHING menu item 20 B BAR SPACING menu item 24 BAR WIDTH menu item 24 C CANCEL key 15 Cleaning 57 back media rollers 57 fan filters 54 front media rollers 56 media transport belt 57 media transport output sensor 57 system exterior 54 Clearing misfeeds 58 Control panel 6 Controller board, part number 22 Controller ID 29 CtServer software functions of, 3 overriding control panel settings, 4 users guide, 4 D DISPLAY ERROR LOG menu item 22 DISPLAY LASER LOG menu item 22 Display messages 30 DISTANCE FROM NOTCH TO LEADING EDGE menu item 28 E ENTER key 15 Environmental specifications 8 Equipment configuration displays 29 EXPOSURE LEVEL menu item 28 Exposure, setting 28, 31 F Fan filters 54 avoid grasping, 7 location of, 7 removing 55 replacing 56 Firmware, version of 22
H Heat, see System specifications HORIZONTAL MAGNIFICATION menu item 17, 28 HORIZONTAL RESOLUTION menu item 26 I Identification label, location of 11 IGNORE LASER TEMPERATURE ERRORS menu item 19 IMAGE LENGTH menu item 26 IMAGE OFFSET (VERTICAL) menu item 26 IMAGE OFFSET menu item 19, 20, 21 INDEXING IS ENABLED menu item 21 Input tray 6 J Jams, see Clearing misfeeds L l 44 Laser classifiication, 9 power of, 29 safety concerns, 9 warning, 9 LEDs green 15
N NEXT key 15 NOTCH DEPTH menu item 28 NUMBER OF PLATES menu item 24 O ONLY 1 PIN BAR IN USE menu item 19 OVERLAP OUTPUTTING AND IMAGING menu item 19 P Parameter settings CtServer vs. control panel, 4 Parameters, setting 16 Pedestal 7 Pin bar ensuring the correct one is used, 38 function of, 5 installing a, 38 not seated correctly 47 ordering an additional, 6 types of, 6, 38 Pinch roller bar guidelines for using, 6 purpose of, 6 Pinch rollers fail to automatically close (System 4x) 52 function of, 6 Plate loading a notch-registered plate
PRE-IMAGE SETTLE TIME menu item 21 PROCESSOR SPEED menu item 19 PROGRAM VERSION menu item 22 R REGISTRATION DELAY BEFORE PINCHING PLATE menu item 20 Registration pins operation of the "hidden" pin 58 the third "hidden" pin 50 the third "hidden" pin, 58 Regulatory information 10 REVERSE IMAGE POLARITY menu item 24 RUN MEDIA ROLLERS menu item 22 RUN TRANSPORT menu item 22 S Safelight requirement 8, 37 SELECT key 15 Sending a job 13 Shutting down the system 14 Specifications, see System specifications Spinner motor 29 START key 15 Starting the system 13 Step wedge test 31 purpose of, 31 test strip, 32 STOP key 15 System components diagram of, 3 list of, 3 System specifications ac power, 8 heat dissipation, 8 humidity, 8 temperature, 8 T TEST PATTERN MODE menu item 24 TEST PATTERN TYPE menu item 24 TEST PATTERNS menu 24 TEST PATTERNS menu item 24 U UNITS OF MEASURE menu item 17 USE THE PLATELINE INTERFACE menu item 20 USE TRANSPORT AS AN OUTPUT TRAY menu item 20 USER MAINTENANCE menu 22
in
in
USER PREFERENCE menu 17 V VERTICAL MAGNIFICATION menu item 17, 28 VERTICAL RESOLUTION menu item 26 W WAITING FOR LASER message 30 Warm-up period 5, 13 Warranty issues 4 Workstation function of, 3 operating instructions for, 3
NOTES