Lotem 400 Family UG en JUN10

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User GuideEnglish

Lotem 400 Family

399Z1N136C

Lotem 400 Family

User Guide

CopyrightCopyright © 2003 Creo Inc. All rights reserved.

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FCC ComplianceThe Creo equipment referred to in this document complies with the requirements in Part 15 of FCC Rules for a Class A computing device. Operation of the Creo equipment in a residential area may cause unacceptable interference to radio and TV reception, requiring the operator to take whatever steps are necessary to correct the interference.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limitation of LiabilityThe product, software or services are being provided on an "as is" and "as available" basis. Except as may be stated specifically in your contract, Creo Inc. expressly disclaims all warranties of any kind, whether express or implied, including, but not limited to, any implied warranties of merchantability, fitness for a particular purpose and non-infringement.

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The text and drawings herein are for illustration and reference only. The specifications on which they are based are subject to change. Creo Inc. may, at any time and without notice, make changes to this document. Creo Inc., for itself and on behalf of its subsidiaries, assumes no liability for technical or editorial errors or omissions made herein, and shall not be liable for incidental, consequential, indirect, or special damages, including, without limitation, loss of use, loss or alteration of data, delays, or lost profits or savings arising from the use of this document... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PatentsThis product is covered by one or more of the following U.S. patents:

.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creo Inc.3700 Gilmore WayBurnaby, B.C., Canada V5G 4M1Tel: 1-604-451-2700Fax: 1-604-437-9891

http://www.creo.com399Z1R513A

Revised June 2003

RE37,3764,558,3024,743,0914,992,8645,049,9015,079,7215,103,4075,111,3085,113,2495,122,8715,124,5475,132,7235,150,2255,153,7695,155,7825,157,5165,208,8185,208,8885,247,1745,249,0675,283,1405,291,2735,323,248

5,325,2175,339,1765,343,0595,355,4465,359,4515,359,4585,367,3605,384,6485,384,8995,412,4915,412,7375,420,7025,420,7225,459,5055,473,7335,481,3795,488,9065,497,2525,508,8285,509,5615,517,3595,519,8525,526,143

5,532,7285,561,6915,568,5955,576,7545,579,1155,592,3095,594,5565,600,4485,608,8225,615,2825,625,7665,636,3305,649,2205,650,0765,652,8045,680,1295,691,8235,691,8285,696,3935,699,1745,699,7405,708,7365,713,287

5,742,7435,764,3745,764,3815,771,7945,785,3095,813,3465,818,4985,854,8835,861,9045,861,9925,875,2885,894,3425,900,9815,934,1965,942,1375,946,4265,947,0285,958,6475,966,5045,969,8725,973,8015,986,8195,995,475

5,996,4995,998,0676,003,4426,014,4716,016,7526,031,9326,043,8656,060,2086,063,5286,063,5466,072,5186,090,5296,096,4616,098,5446,107,0116,112,6636,115,0566,121,9966,130,7026,134,3936,136,5096,137,5806,147,789

6,158,3456,159,6596,164,6376,180,3256,181,3626,181,4396,186,0686,189,4526,191,8826,204,8746,208,3696,214,2766,217,9656,260,4826,266,0806,266,1346,267,0546,268,9486,283,5896,295,0766,299,5726,318,2666,352,816

6,353,2166,366,3396,371,0266,377,7396,387,5976,396,4226,396,6186,407,8496,414,7556,422,8016,435,0916,441,9146,450,0926,456,3966,476,9316,477,9556,509,903

http://www.creo.com

Using This Manual viiScope of This Manual ............................................................................................................................. viii

1 Introduction 1Lotem 400 Overview ................................................................................................................................ 2Platesetter Front View............................................................................................................................... 3Platesetter Rear View................................................................................................................................ 4Typical Customer Site Configuration......................................................................................................... 5Data and Communication Flow ................................................................................................................ 7Turning the Platesetter On and Off ........................................................................................................... 8

2 PC Controller User Interface 11Overview ................................................................................................................................................ 12User Interface ......................................................................................................................................... 13Status Indicator ...................................................................................................................................... 14Operation Toolbar .................................................................................................................................. 15

Routine Functions Menu .................................................................................................................. 15Utilities Menu .................................................................................................................................. 17Settings Menu ................................................................................................................................. 19Stop button ..................................................................................................................................... 19

Online Machine View ............................................................................................................................. 20

3 Plate Handling 23Media Definition..................................................................................................................................... 24Loading Plates ........................................................................................................................................ 26

Loading Plates via the Workstation .................................................................................................. 26Loading Plates Manually .................................................................................................................. 29

Plate Geometry....................................................................................................................................... 30

4 User Troubleshooting 33Generic Troubleshooting Questions ........................................................................................................ 34Startup Problems .................................................................................................................................... 35

PC Does Not Boot............................................................................................................................ 35Windows Does Not Launch.............................................................................................................. 35Windows Does Not Start.................................................................................................................. 36

Calling Response Center For Support...................................................................................................... 36Plate Loading Failure............................................................................................................................... 37

Releasing Stuck Plates...................................................................................................................... 37Double Loading ............................................................................................................................... 41

Contents

vi Lotem 400 Family User Guide

Punch is Stuck ................................................................................................................................. 43Drum Related Errors ........................................................................................................................ 44Error Message: Plate Did Not Reach Punch Position.......................................................................... 45Error Message: Vacuum Did Not Grab Plate ..................................................................................... 46Error Message: Drum Fly-off ............................................................................................................ 47Error Message: Illegal Plate Size ....................................................................................................... 48Error Message: Illegal Gripper Width................................................................................................ 48

Plate Unloading Problems....................................................................................................................... 49Plate Does Not Unload..................................................................................................................... 49Unload Failure After Plate Restart .................................................................................................... 51

Exposure Failure Problem........................................................................................................................ 51Exposure Does Not Start .................................................................................................................. 51

Communication Problems with TSP Board .............................................................................................. 52

Index 53

Using This Manual

Scope of This Manual........................................................................viii

viii Using This Manual

Scope of This ManualThe Lotem 400 Family User Guide provides you with the basic information you need to begin production with the Lotem 400 platesetter.This guide includes two main parts, as detailed below.

Lotem 400 platesetter and PC Controller user interface

• Introduction to Lotem 400 platesetter

• Getting started

• PC Controller user interface

• Plate handling

Note: Lotem 400 Family in this document refers to the Lotem 400 and the Lotem 400 Xpose. Unless otherwise specified, Lotem 400 refers to both machines.

If you are running a Brisque to Lotem 400 workflow, please see the Brisque to Lotem Family Connectivity User Guide, 399Z3R084A.

For a complete description of the Brisque functionality, see the Brisque User Guide version 4.0:

Part 1 399Z50677DPart 2 399Z50678D Part 3 399Z51124CPart 4 399Z51956B

If you are running an Xpose to Lotem 400 workflow, please see the Lotem 400 Xpose User Guide.

The safety precautions that must be followed when using the Lotem 400 platesetter are detailed in a separate document. See Lotem 400 Family Safety Precautions for User, 653-00275A.

For details regarding the MCU for Lotem 400 see MCU for 400 Family User Guide, 653-00118A.

Introduction

Lotem 400 Overview...........................................................................2

Platesetter Front View .........................................................................3

Platesetter Rear View ..........................................................................4

Typical Customer Site Configuration....................................................5

Data and Communication Flow...........................................................7

Turning the Platesetter On and Off......................................................8

2 Chapter 1 – Introduction

Lotem 400 OverviewThe Lotem 400 platesetter is a Creo thermal imaging platesetter. It represents state-of-the-art technology within all operational systems, and features a technological breakthrough in the form of a multi-beam, variable resolution thermal imaging head. Within the footprint of a typical 4-page imagesetter, the Lotem 400 platesetter with optional multi cassette unit (MCU) provides full automation including slip sheet removal, customized plate punching, and plate loading/unloading. It has a fast rotating external drum and a thermal imaging head.

The thermal imaging head inside the Lotem 400 platesetter is comprised of a 24 laser beam array operating at a wavelength of 830 nanometers. Individual beams are precisely positioned using a self calibrating alignment configuration, and this allows for continuously variable imaging resolutions.

A significant and unique feature of the Lotem 400 platesetter is dynamic drum balancing which guarantees rotational stability of the external drum. The supported plate size range, around the drum x along the drum, is from minimum 311 x 228 mm (12.25 x 9 inch) up to maximum 622 x 750 mm (24.5 x 29.5 inch).

To allow for variable resolution imaging, drum rotation speed is programmed to vary proportionally with the output resolution. This particular feature is unique to Lotem 400 platesetter, and ensures optimized imaging speeds based on output parameters.

The Lotem 400 platesetter front end is the Brisque or Prinergy. In addition to standard Brisque Impose features, special features for CTP users, such as fast plate remake and back/front preview were added. The Lotem 400 platesetter system can accept data from any standardized digital file format including PostScript™, EPSF, PDF™, TIFF-IT, and CT/LW files.

Platesetter Front View 3

Platesetter Front View

Figure 1: Lotem 400 platesetter (manual) front view

Loading tray – for loading a plate into the platesetter.

Front door – opening is controlled from PC Controller monitor.

Right side door – access to electronic box and PC Controller.

Front door

Right sidedoor

Loading tray

The Lotem 400 is now available with a multi cassette unit (MCU) for automated loading. For details see MCU for Lotem 400 Family User Guide, 653-00118A.


Platesetter Rear View

Figure 2: Lotem 400 platesetter rear view

Rear door – opening is controlled from PC Controller monitor.

Plate exit – through which plates are unloaded after processing.

On/Off pushbuttons – to power up and shut down the platesetter.

Main circuit breaker – before you power on the platesetter, make sure main circuit breaker is on (set to 1). For total disconnection from the mains supply, set the main circuit breaker to 0.

2 on/off pushbuttons

Rear door

Main circuit breaker

Plate exit

Typical Customer Site Configuration 5

Typical Customer Site ConfigurationA typical customer site configuration with the Lotem 400 platesetter is shown below.

Figure 3: Typical configuration at customer site

Plate room

Workflowworkstation

PC controllermonitor

Lotem 400 Processor

Conveyor


The platesetter room may include:

• Lotem 400 platesetter

• PC Controller monitor; the user interface of the PC Controller that controls the platesetter operation.

• Workflow workstation; jobs for the Lotem 400 platesetter are processed by the workstation.

• Conveyor; moves the unloaded plates to the Processor.

• Processor; option not supplied by Creo and intended for plates that need processing after expose.

Note: The Plate stacker (for collecting unloaded plates) and Pre-heat oven (for plates that require heating), not supplied by Creo, are not shown in the figure.

Data and Communication Flow 7

Data and Communication FlowJob data is sent from the workstation, which is connected to the PC Controller. The figure below shows the data and communication flow between the workstation and the platesetter.

Figure 4: Communication & data flow between platesetter & workstation

Workflowworkstation

PC controllermonitor

Dat

a ca

ble

(TS

P)

Network TCP/IP100B/T

Data from prepress

Lotem 400

Poi

nt to

poi

nt


Turning the Platesetter On and OffTo turn on the Lotem 400 platesetter:

1. Check the air pressure gauge (see figure below) in the air pressure unit. Make sure the air pressure is 6 ATM (88 psi).

Figure 5: Air Pressure unit

2. Make sure the main circuit breaker is on, that is, set to 1 (see Figure 2 on page 4).

3. On the rear panel, press the two (2) on/off pushbuttons so that they are both lit (see in Figure 2 on page 4).

4. Press the on/off pushbutton on the PC Controller monitor.

Important: When power is interrupted, the platesetter shuts down. To continue working when normal power returns, you must press either of the two yellow on/off pushbuttons twice (once to “turn off” the platesetter and once to turn it back on) as shown in Figure 2 on page 4. The pushbutton lights up and the platesetter restarts.

Note: Turn on the platesetter before turning on the workflow workstation.

Turning the Platesetter On and Off 9

5. Double-click the Lotem400 icon on the PC desktop.

6. Turn on the workflow workstation.

To turn off the Lotem 400 platesetter:

1. In the PC Controller software, click Routine Functions.

2. From the Routine Functions menu, select Shut Down.

3. In the Confirm message, click Shut Down.

4. From the Start menu of your Windows, click Shutdown.

5. When the message It is safe to turn off your computer appears, press the on/off pushbutton on the rear panel of the platesetter.

PC Controller User Interface

Overview ..........................................................................................12

User Interface ...................................................................................13

Status Indicator.................................................................................14

Operation Toolbar .............................................................................15

Online Machine View........................................................................20

12 Chapter 2 – PC Controller User Interface

OverviewThe PC Controller monitor is your interface with the Lotem 400 platesetter; it monitors the platesetter operation, is constantly updated with the machine status and provides machine information. The platesetter is controlled by the PC Controller located inside the platesetter; the monitor resides on a nearby table, as shown in Figure 3 on page 5. The job data is sent from the workstation, that is connected to the PC Controller (see Figure 4 on page 7).

Figure 6: PC Controller monitor

User Interface 13

User InterfaceThe PC Controller monitor is your basic working area, where the application indicators, buttons, popup menus and windows appear.

The workflow-oriented platesetter user interface is intuitively designed, and minimal computer knowledge is required. The following features support this design:

• Color-coded Status indicator indicates the machine status. For example, if a problem occurs while you are away from the monitor checking exposed plates, the problem indications on the screen are visible from a distance.

• Large interface indicators can be seen from a distance, so you can be alerted even when working away from the monitor.

• Monitor screen is divided into functional areas, as shown in the Main window figure below.

Figure 7: Main window areas

Operation toolbar

Messagearea

Status indicator

Interlockindicator

Online machine view


Status IndicatorThe Status indicator is fairly large and color-coded for easy identification. The indicator updates you on machine status even when you are performing tasks away from the monitor. For example, you can easily see when the Status indicator changes to Attention.

Start up (green) – machine is performing start up. All machine components go to Home position.

Off-line (gray) – like Ready, but you cannot expose plates or run calibration tests; all other functions are available. After Start up and Stop, the machine automatically goes to Off-line. Click On-Line button on the Routine Functions menu to set machine to Ready.

Ready (blue) – the machine is ready for operation and in On-Line mode; you may load a plate and begin the expose job.

Working (green) – the machine is busy exposing the current job. While the machine is working, you can place another plate on the loading tray or send additional jobs from the workstation.

Attention (red) – the machine has stopped working and requires your intervention, or has encountered a problem that requires servicing. A message appears in the message area and normal operation resumes only after the problem is solved.

Service (purple) – a door is open or a panel was removed (the Interlock indicator appears on the Main window) or the machine is being serviced. If a door is open, the Online machine view shows the open door.

Operation Toolbar 15

Operation ToolbarThe Operation toolbar to the right of the Status indicator is used to access all the operational options required when working with the platesetter PC Controller application. The Operation toolbar includes the Routine Functions, Utilities and Settings buttons used to open the relevant menus and the Stop button, as described below.

Routine Functions Menu

Click the Routine Functions button to open the Routine Functions menu. The menu includes operations that are routinely performed by the user when working with the machine, as described below.

Sub-menu option Description

Open Front Door

1. Click this button to open the front door.

2. The door locking mechanism is released for 30 seconds. During these 30 seconds push the door slightly inward.

3. The door releases. Lift the door to open it completely.

When the front door is open, the safety interlocks are activated. As a result, machine systems such as drum motor and laser system do not operate. The machine is in Service mode (Status indicator is purple) and the Interlock indicator appears below the Status indicator with the name of the open door.

Note: You can interactively open the door by clicking on the front door in the Online machine view

Open Rear Door

The rear door opening is similar to opening the front door.


Unload Plate

This operation is available only when there is a plate on the drum and the machine is not working.

In normal operation this option is not used since plate unloading is automatic. However, if the plate was not loaded properly or the expose process was not completed, you can manually initiate plate unloading. Click Unload Plate.

Messages

Click Messages to open the Message dialog box. When problems are encountered during machine operation, error messages are listed in the Message dialog box. The dialog box automatically opens whenever an error is recorded and the current error message is highlighted. All error messages recorded during the current run are listed.

Note: To view the full message, double-click the vertical line in Description heading or manually resize the column.

The Message dialog box has four buttons: Up/Down arrows for scrolling to previous/next messages; Reset to reset the machine after solving the problem that caused the error message (see Reset Machine); Help ? to launch the application online help system.

Reset Machine

Click this button when there is a need to reset the machine. For example, a problem that caused the machine to stop has been solved. The system prompts you to confirm the reset. The machine then resets to Ready, Off-line or Working status, depending on the status prior to the reset.

Note: Reset machine on the Routine Functions menu is the same as the Reset button in the Message dialog box.



Utilities MenuClick the Utilities button to open the Utilities menu. The menu options are described below.

On-line

When the Status indicator is Off-line, you cannot expose plates. To expose plates, click On Line and wait until the machine resets to Ready.

Shut Down

Use this option for normal machine shutdown. See Turning the Platesetter On and Off on page 8.



Expose Params

The Expose Info window lists expose-related machine parameters. You may open this window anytime before or during exposure.

Log Files

Four windows open: Machine task list, two Log message windows (for service usage) and Expose queue list (data sent from the workstation).

Machine Info

PC Controller software version

Hardware

Lists the machine hardware parts

Setup Tables

The Plates Setup tables list the Intensity and Speed values for each plate. You can change the values. For example, in case of under exposure, you can increase intensity or speed for the resolution value in the expose.


Diagnostics

Currently not supported.

Remote Support

When you click the Remote Support button, the following appears:

Confirmation will allow the service engineer to work by remote with the user.

Users

Defines the type of user (some application settings and preferences are available only for service and R&D). Click Users to open the Define User dialog box, and choose user type – user, service or R&D. Then enter your password and click OK.



Settings MenuClick the Setting button to open the Settings sub-menu. The sub-menu options are described below.

Stop buttonThe Stop button on Operation toolbar is used in case of an emergency stop. The drum and all the machine operations are immediately stopped, and the plate remains in its current position.


Media Definitions

Media definitions is used to define the type of plates you will be using. (the plate must be defined before it is loaded). This option is also used to edit the parameters of existing plates or to delete plates you will no longer use. For details see Media Definition on page 24.

Preferences

Preferences is used to define various settings. In the Preferences dialog box, you can set the following:

Units – choose cm or inch to set units of measurement for all measurements, such as plate dimensions and thickness.

Language – only English is implemented.


Online Machine ViewThe Online machine view shows the platesetter during operation; it enables you to see a simulation of machine operation. The main features are described below.

Operational stage

When the machine is in Working status, you can identify the current operational stage. You can see the plate loading onto the drum and the rotating drum. The remaining process time is indicated on the Progress indicator.

Interlock indication

When a door is open or a panel is removed, a safety interlock is activated. The Status indicator shows Service (purple) and the Interlock indicator appears below it with the name of the activated safety interlock. For example, a door is open, a panel is removed or a laser interlock is activated.

Figure 8: Main screen with Service status, interlock indicator and open doors

For details on safety interlocks see Lotem 400 Family Safety Precautions for User, 653-00275A.

Online Machine View 21

Attention

When the machine status is Attention, the Online machine view may give some indication as to the cause of the problem. For example, if the plate is jammed inside the machine.

Perform interactive operations

You can open the front or rear door by clicking on the relevant door on the Online machine view. (This is the same as using Open Front door and Open Rear door on the Routine Functions menu.)

Figure 9: Main screen with front door green when the cursor moves on it

Note: When you move the cursor on the door it becomes green. See figure below.

Plate Handling

Media Definition ...............................................................................24

Loading Plates...................................................................................26

Plate Geometry .................................................................................30

24 Chapter 3 – Plate Handling

Media DefinitionYou must define the type of plates you will use before loading them into the platesetter. This option is also used to edit the parameters of existing plates or delete plates you will no longer use.

Click Media Definitions in the Settings menu to open the Media Definition window. Defined plate types are listed under Media list.

Define new media:

1. Click New.

2. In the Name box, assign the media name. Recommended media name includes the manufacturer name.

3. From the Manufacturer list box, select the manufacturer’s name.

Note: The plate names in the window are only examples. The platesetter supports plates of various specifications and various vendors, and Creo does not promote specific companies’ plates.

Media Definition 25

4. From the Type box, select Positive or Negative. This parameter is important for the Exposure type. For example, for a positive plate (that is, negative working plate), choose Positive and perform a negative exposure.

5. In the Height box, type the height in millimeters. Maximum media height is 622 mm.

6. In the Width box, type the width in millimeters. Maximum width is 750 mm.

7. In the Thickness box, type the media thickness as listed on the plate packaging. You must verify the media thickness with a micrometer.It should range: 0.15 – 0.3 mm.

8. The Focus Value is automatically updated according to the media thickness you entered in step 7.

9. In the Sensitivity box, type the value supplied by the plate vendor. This value is important for the initial adjustment of the optic system.

10. In the Res/Int Table, select the value for your media.

11. In the Res Mtr Table, select the Res Motor Table according to your media.

12. Click Save to save the new media. The new plate name will then appear in the Media list.

To modify the parameters of existing media:

1. From the Media List, click the media whose parameters you want to modify. The selected media parameters appear in Media Parameters.

2. Modify the parameters as explained in Define new media: on page 24. You can modify all media parameters, except the plate name (Name field is grayed).

3. Click Save to save the new parameters.

To delete a media set from the Media list:

From the Media List, click on the requested plate and click Delete.

Note: To change the media name, you must first Delete the media. Then click New to configure it again.


Loading Plates

Loading Plates via the WorkstationThe Lotem 400 platesetter has a semiautomatic plate loading process. When an expose job is initiated by the workstation the requested plate is placed at the center of the loading tray, emulsion side down. When the Loading plate pushbutton is pressed and the machine is ready to expose, the plate is automatically loaded into the platesetter.

1. Define an Expose job on the workstation (see Brisque to Lotem Family Connectivity User Guide, 399Z3R084A).

2. A message is sent from the workstation to the PC Controller requesting that an appropriate plate be loaded in the platesetter. The message on the application Main window specifies the plate thickness and size.

Figure 10: Message on PC Controller sent from workstation

3. Get the requested plate.

4. Place the plate on the loading tray (emulsion side down). Note the printed vertical scale on the tray; its numbers are plate width sizes. Make sure to align both sides of plate with the scale markers that correspond to plate width.

Loading Plates 27

Figure 11: Loading plate tray

5. Either click OK on the message (see figure 9) or press the Loading plate pushbutton to initiate plate loading (see figure 10).

When the machine is ready to expose, the plate is automatically loaded onto the drum.

6. After the plate is loaded into platesetter, you can place another plate on the loading tray, ready for next expose job (if the plate size is known). The new plate is automatically loaded when the machine is Working status. If you did not place a new plate on the tray then a

scale in inches

scale inmm

Loadingplate pushbutton

Plate on tray

Note: The location of the scale markers is such that the marker is visible on both sides of the plate when a plate that corresponds to that size is placed on tray. For example, when a plate that is 15 inches wide is placed correctly the 15 inch marker on each side is visible.

The figures on page 28 show a small and large plate on loading tray.


message will appear when the machine is ready. Place the plate on the tray and press OK. A message appears after every separation requesting you to load the next plate.

Figure 12: A small plate on loading tray

Figure 13: A large plate on loading tray

Loading Plates 29

Loading Plates ManuallyTo manually load plates:

1. Define the media on the PC Controller (see Media Definition on page 24).

2. From the Utilities menu, select Hardware.

3. Double-click Loading System.

4. In the Media To Load list, choose the type of media you want to load.

5. Get the plate you want to load.

6. Place the plate on the loading tray (emulsion side down). Note the printed vertical scale on the tray; its numbers are plate width sizes. Make sure to align both sides of plate with the scale markers that correspond to plate width.

7. Push the plate inwards until both edges reach the loading stopper door inside the platesetter.

8. In the Loading System dialog box, click Load. Make sure Media on Drum is None. The plate is loaded.

Figure 14: Loading system window


Plate GeometryThis section describes aspects of the plate geometry and image area. These aspects will help you plan for the plate exposure process and define correct settings for your press and plate, and your image offset.

The figure below shows a negative working plate, where two strips of emulsion remain – 10 mm at the head margin and 6 mm at the tail margin.

Figure 15: Negative working plate – various plate dimensions

Head margin – defined on the workstation, as one of the press format parameters. It defines the distance from the plate edge until the beginning of the layout or the exposed image. This parameter is also known as leading edge to print.

Tail margin – defined on the workstation as one of the press format parameters. It defines the distance from the back edge of the plate to the edge of the file or layout.

H (height) – plate height (around the drum).

W (width) – plate width (along the drum width).

max. plate size = 750 x 622max image area = 750 x 606

head marginmin 10 mm

tail marginmin 6 mm

head gripperhead margin

750 mm

622 mm 606 mm

Plate Geometry 31

In a negative exposure of a positive working plate, there is always an emulsion area on the plate that is not exposed, therefore emulsion areas remain. The size of these areas is determined as follows:

• At the head, the area is equal to the width of the plate and at a height of up to 10 mm.

• At the tail, the area is equal to the width of the plate and at a height of up to 6 mm.

The image alignment is determined by the Alignment, as defined in the Plate Expose window on the workstation. For details, see the Brisque to Lotem Family Connectivity User Guide, 399Z3R084.

User Troubleshooting

Generic Troubleshooting Questions ...................................................34

Startup Problems...............................................................................35

Calling Response Center For Support ................................................36

Plate Loading Failure .........................................................................37

Plate Unloading Problems..................................................................49

Exposure Failure Problem ..................................................................51

Communication Problems with TSP Board .........................................52

34 Chapter 4 – User Troubleshooting

Generic Troubleshooting QuestionsThere are several troubleshooting steps that you should complete before calling the Response Center. These steps can prevent extensive down-time by enabling you to solve problems independently. You will find these steps are fully explained in the relevant troubleshooting document. Ideally, the customer will have completed these steps before calling the Response Center, and also reviewed the following questions and written the answers down. If after completing these steps you find that the problem is not resolved, please answer the following questions before calling the Response Center. Write down your answers and have them available during your call.

The questions are as follows:

• When was the last time the machine worked properly?

• What was done since then? For example:

Was the machine moved?

Was the machine cleaned?

Was a new batch or type of plates used?

• Was an error message displayed on screen? If yes, what did it say (include numbers, if any).

• What is the software version?

• Does the problem happen all the time (with all plates), or just some of the time? For example:

With a particular plate brand, type and/or size?

Only when a few plates are left in the cassette?

• Does the problem seem to be a random occurrence?

• What are the temperature and humidity levels in the plate storage room? For example:

Do they adhere to the plate manufacture’s guidelines? If not:

• In what ways?

• Does the temperature fluctuate radically?

Startup Problems 35

Startup ProblemsFollowing are the most common start up problems:

• PC does not boot

• Windows does not start

• Windows does not launch

• Lotem application aborts

PC Does Not Boot1. Verify that all power circuit breakers are in the ON position.

2. Verify that both on/off buttons at the rear of the platesetter (yellow pushbuttons) are in the out position and lit.

3. Verify that the PC monitor power is ON.

Windows Does Not LaunchWindows does not launch and the error message relates to missing or corrupted files.

1. Continue the startup and follow the screen instructions. Wait until the Windows startup is complete. Then perform Windows shutdown and reboot the PC.

2. If the startup fails and the PC hangs:

• Press F1 during initial startup and choose Safe Boot.

• Run a system check/test from AccessoriesDisk/ToolScan/Disk.

3. In some cases, Scan Disk will not resolve the problem. In such cases, you may need to reload the following files onto your hard disk: first Windows, then drivers, and finally the Lotem application. Please contact your service representative for details before you proceed.


Windows Does Not StartWhen Windows does not start and the error message relates to boot disk/diskette:

1. Open the rear door by inserting a long screwdriver into the holes (on both left and right sides).

2. Open the right side door and make sure that a diskette was not left inside the diskette drive.

Calling Response Center For Support

Whenever you need to call Creo service representative for help, the following information should be supplied. This information is important for addressing your problem.

• In case of an error in the PC Controller application, write down the first five (5) error messages that are listed in the Message window of the PC Controller main window.

• In case of error in the Brisque application, write down the Brisque error number and message.

• In case of loading/unloading failure, write down the plate location, if known.

• Write down the Brisque Job information (Job type, number of separations, Screen set that is used and LW/CT resolution).

Plate Loading Failure 37

Plate Loading Failure

The following are the most common plate loading failures:

• Plate is stuck

• Double Loading

• Drum related errors

• Punch is stuck

The following are the most common error messages:

• Error Message: Plate did not reach punch position

• Error Message: Vacuum didn't grab plate

• Error Message: Drum Fly-off

• Error Message: Illegal plate size

• Error Message: Illegal gripper width

The following sections describe the actions that you should take when the above failures occur.

Releasing Stuck PlatesPlates may get jammed inside the platesetter during plate loading. As explained in Loading Plates Manually on page 29, the message sent from the workstation to the PC Controller requests you to load a plate of specified size and thickness. If you load a plate with an incorrect height value, the plate will get jammed and cannot be properly loaded onto the drum. In this case, you will need to manually remove the jammed plate. Special precautions are required when performing this procedure.

CAUTION: When handling the plates, especially if you need to release them, be sure to wear protective gloves as the plate edges are sharp.

Note: Before removing a plate, remove objects or clothing that might get caught in the revolving drum or other moving parts, such as, ties and jewelry. Fold long sleeves and gather long hair.

Note: Before removing a plate, switch off the main drum power switch on the Distribution box.


When plate loading fails because of incorrect plate size, the Status indicator is Attention and the message window opens with the message “Illegal plate size”.

To manually release the stuck plate:

1. You first need to open the upper door from the main window: to interactively open the door, click on the rear door on the Machine online view. Alternatively, click Open Rear Door from Routine Functions menu.

2. When the rear door is open, stand at the rear side of the platesetter and rotate the drum forward, towards the front of the platesetter.

3. Rotate the drum until you can see the detached edge of the plate, that is, the edge that is not held by the tail grippers.

4. Hold the detached edge of plate and gently pull it towards you until you can see the other edge of the plate, that is, the edge that is held by the head grippers.

5. To release the plate from the head grippers: hold both sides of plate (left and right) and pull the plate abruptly towards you.

Note: The plate edges are sharp so the plate should not be handled with bare hands. Wear gloves before attempting to release the plate.

Note: It is recommended to release the entire plate as one piece; do not attempt to cut the plate.

Note: Released plates must be disposed; you may not re-use the plate.

Note: Plate remnants left in the platesetter may cause mechanical and laser radiation hazards!


6. Verify that the tail gripper did not move. If it did, then move it to the Preload position (0). To do this,

a. Drag the tail gripper to the preload position (as shown in the picture below).

b. In the Hardware dialog box, open the Loading system directory.


c. Double-click Loading system.

d. In the Loading System dialog box, click Restart Plate State.

e. Click Drum Init.

f. Click Pre-load (in the same dialog box) to move the tail gripper to the correct position according to the defined plate size.

The status indicator shows Ready (blue).

7. Close the rear door.

8. Close the loading system and hardware windows.

9. Click the Reset button in the message window, and then Reset in the Confirm message that appears.

Machine status is now Ready and you can proceed to loading the correct plate size.


Double Loading

1. If the plates are in the cassette to punch area:

• Gently try to push them back into the cassette.

• If this is not possible, open the upper cover, remove the plates and place paper in between them and then place the plates back into the cassette.

• In the Hardware window, select Loading System/Loading System to open the Loading System window.

• In the window, click Restart Plate State.

2. If plates are stuck halfway on the drum:

• Open the rear door.

• Then using your hands, slowly rotate the drum away from you (towards the cassette) until you can see the plate tail edge. (A metallic noise might be heard, which is caused by the edge being dragged on the roller system.)

Tip: Open the front door and look into the loading area in order to find out whether double loading has occurred.


3. If the plates are held by a tail gripper(s):

Figure 16: Tail gripper

• Release the gripper(s) from the plate.

• Hold the edges of both plates and pull the plates towards you until the head gripper is visible.

• Then, press on one or two head grippers while pulling the plates abruptly.

• Completely remove the plates from the drum.

• In the Hardware window, select Loading System/Loading System to open the Loading System window.

• In the window, click Restart Plate State.

• Move the gripper to Preload position (see Plate Geometry on page 30). Open the loading system and define a plate and press pre-load.

4. Occasionally, a batch of plates may be problematic and a source for excessive static electricity. This may cause plate-loading problems.

Tip: To minimize the probability of double loading, make sure the room temperature is maintained between 21 to 25 degrees, and humidity is approximately 55%.


Punch is StuckIf the punch gets stuck while punching a plate, try the following:

Figure 17: Punch system

1. Remove the plate. If you cannot remove it, the punch pin may still be in its low position in the plate.


2. If this is the case, you need to release the punch:

Make sure the doors are closed.

In the Hardware window, select Punch System/Punch Motor/Punch Motor xx (where xx is the punch number) and Punch System/Detector/Punch Motor #Home Pos.Det.

The punch numbers proceed from left to right.

If you are not sure which punch needs to be released, open the front door and remove the plate and close the door. Then activate the punches one by one by clicking Start, to see which is the problematic punch. If the Home Position does not change to ON, then that is the problematic punch.

If the plate is stuck and you cannot remove it, then activate the punches one by one by clicking Start, to see which is the problematic punch. If the Home Position does not change to ON, then that is the problematic punch.

If you discover a problematic punch, contact your service representative.

Drum Related ErrorsPlate loading fails with drum related error Drum did not reach position or Load Gripper is protected by Load Gripper Protector. There may be several causes to this error message. Check the following possibilities:

1. Verify that all covers and panels are properly closed. Make sure that no interlock is active (that is, an interlock indicator does not appear on the main application window, and the machine status is not Service).

2. Verify that the air compressor supply to the platesetter is adequate (minimum setting of the air compressor should be 6 Bar).

3. From the Hardware window, select Loading System/Loading System. In the Loading System dialog box, click Drum Init.


Error Message: Plate Did Not Reach Punch PositionPlate loading fails with error message: Plate did not reach punch position.

1. Verify that the plates are properly centered in the cassette (both side brackets touch the plate sides) and the rear bracket is approximately 1 mm from plate edge.

2. Check if the plate edge is bent, cut or coated with glue. This may cause the short pins to fail a plate reading when the pins are supposed to touch the plate (these are the centering system pins and/or the pins near the punch blocks). Try rotating the plate 180 degrees. This may help to verify if the plate edge is the cause of the problem.

3. Look through the cassette entrance towards the punch block units.

4. If you can see a punch pin in the middle of the punch slot, this means that a plate may get stuck on its way to the punch. In this case, contact your service representative.

Figure 18: Punch

punch slot


Error Message: Vacuum Did Not Grab PlatePlate loading fails with error message Vacuum did not grab plate. Open the front door and check the plate location. The cause and solution to this problem depends on plate location:

1. Verify that the air compressor supply to the platesetter is adequate (minimum setting of the air compressor should be 6 Bar).

2. Open the cassette door. If you can see the plate inside the cassette, verify that the plate edge is not under the two side brackets. In this case, the plate cannot be loaded. Try to reposition the plate in the cassette or add more plates into the cassette.

Figure 19: Centering system

3. Verify that the loading bar is horizontal to the plate (see below). Push the bar toward the drum until it touches the two vertical metal brackets. The loading bar should be parallel to the brackets on both axes. If it is not parallel, contact your service representative.


Figure 20: XY Bar

4. If the plate is partially out of the cassette, check that all the Vacuum suction cups on the XY bar are intact, complete and are not torn. If there is a problem with the suction cups, contact your service representative.

5. If the plate is halfway onto the punch blocks, examine the front edge of the plate. If there are bends or dents in the plate, these may be as a result of the plate hitting one of the punch blocks as it is loaded from the cassette. Remove the plate and rotate it in the cassette.

Error Message: Drum Fly-off1. Open the rear door, and manually remove the plate.

2. Move all tail grippers to the end of their slots (near the head grippers). Make sure that the tail grippers are not moved beyond the head gripper holes.

3. Verify that the load/unload rollers are in their proper position (they did not separate from the springs).

4. Close the doors.

5. From the Hardware window, select Loading System/Loading System, and click the following: Restart Plate State, Drum and New Plate.


6. Resend the job from the Brisque.

Error Message: Illegal Plate SizeThere may be several causes to this error message. Do the following:

• Measure the plate in the cassette.

• Verify that the plate size defined in the Off-line/Current Cassette dialog box is the plate size that was actually loaded into the cassette. Plate size should be within +/-1 mm of the dimensions defined in the Media Definition dialog box.

• Clean the centering pins.

• Check the plate edges where the centering pins touch, see if there are bumps, dents, dirt, glue etc... - this could prevent any electrical contact from occurring.

Error Message: Illegal Gripper WidthThere may be several causes to this error message. Check the following possibilities:

1. Make sure no paper accompanied the plate to the centering system.

2. Open the front door and manually remove the plate from the drum. For instructions, see Releasing Stuck Plates on page 37.

3. Move all tail grippers to the end of their slots (near the head gripper). Make sure not to move them beyond the head gripper holes.

4. Close the front door.

5. From the Hardware window, select Loading System/Loading System.

6. In the Loading System window that is displayed, click New Plate.

7. Clean the two red LED sensors located on both sides of the drum chassis using a dry cloth (see below).

Plate Unloading Problems 49

Figure 21: Side to side detector

Plate Unloading ProblemsPlate unloading problems may be caused by one of the following:

• Plate does not unload from the platesetter

• Unload failure after plate restart

Plate Does Not Unload1. Make sure that the previous plate entered the processor correctly.

2. If it did not, this plate may be blocking the conveyor sensor. Verify that the processor is in Ready state, and clear any error message on the processor panel.

3. If there is still a problem, contact the processor technician.

4. Move the previous plate into the processor. Then, from the Routine Functions menu, click Unload Plate to manually unload the current plate.

5. Check that there are no error messages relating to Vibration or Fly Off. If there are such messages, please contact your service representative.


6. Try to manually unload the plate. Then load and unload a different plate size. If this goes smoothly then there may be a specific problem with the original plate size.

Figure 22: Unloading system

7. Load the plate into the processor. Then examine the plate to see if it was partially exposed, or not exposed at all. If it was partially exposed, this can indicate a problem with the exposure sequence and not a plate-unloading problem.

Exposure Failure Problem 51

Unload Failure After Plate RestartIf you have a problem performing Restart Plate State while there is a plate on the drum, then you will not be able to expose the plate or unload it, because Restart Plate State resets the plate status to No plate on drum. To resolve this problem, click Force Plate On Drum to force the system to acknowledge the plate on the drum. Then, you can either expose the plate or unload it.

Exposure Failure Problem

Exposure Does Not Start Exposure does not start at all and the error messages relates to the Host. There may be several causes to this error message.

1. Verify the machine is ON and in Ready mode.

2. On Brisque, go to Devices > Platesetter; select Lotem > Lotem 400.

3. Click the Reconfigure button.

4. In the Queue Manager, a red blinking icon appears on the upper part of the dialog box indicating an error. From the Tools menu, select Operate Control > Plate Expose > Lotem 400.

5. Click OK.

If the blinking icon disappears, then send another expose job. If not, in the In Queue area, select the problematic error message. Double-click it to receive an explanation of the problem.

Important: Never use Force Plate On Drum before performing a visual check that there is actually a plate on the drum.

Note: Make sure there is no error message on the PC Controller.


Communication Problems with TSP Board1. Verify that the Data cable is securely connected to the workstation.

2. Check that the Network or the Point-to-Point cable between the platesetter and the workstation is properly connected.

3. Check if you can ping the platesetter from the workstation:

• Open the terminal window on the workstation

• On the PC, open Settings/Control Panel/Network/TCPIPP/Properties and type ping 192.9.200.2.

To stop the ping sequence type: CTRL+C.

AActive interlock name, 20Air pressure unit

gauge, 8Attention status, 14, 21Automatic plate loading, 27

BBrisque, 26Brisque Impose, 2

CConveyor, 6Customer site configuration, 5

DData & communication flow, 7Define user dialog box, 18Defining new plates, 24Deleting plates, 25

EEmergency stop, 19Emulsion area, 31Error messages, 16Expose Info window, 17Expose queue list, 17Exposed image area, 30

FFront door, 3

HHead grippers, 38Head margin, 30

See also Margins

IIncorrect plate size, 38Interactive operations, 21Interlock indication, 20

Interlock indicator, 14

JJammed plate

precautions, 37releasing, 37

LLanguage, 19Leading edge to print, 30Loading plate on tray, 26, 29Loading plate pushbutton, 26Loading Plates

manually, 29via workstation, 26

Loading tray, 3, 26markers, 26, 29

Log Files, 17Log message window, 17Lotem 400

Front End, 2front view, 3plate size, 2power up, 8product overview, 2rear view, 4shutdown, 9

Lotem 400 with MCU, 2

MMachine parameters, 17Machine reset, 16Machine simulation, 20Machine status, 14Machine task list, 17Main circuit breaker, 4Main window, 13

active (green) door, 21Manual drum rotatation, 38Manual plate unloading, 16Manually loading plats, 29Message dialog box, 16Messages, 16

NNegative plate, 25Negative working plate, example, 30

OOff-line status, 14, 17On/Off pushbuttons, 4Online help, 16Online machine view, 20Open front door

interactively, 21Open rear door

interactively, 21Operation menu, 15

PPC Controller

user interface, 13PC Controller monitor, 6, 12Plate automatic loading, 27Plate exit, 4Plate Expose on Brisque, 31Plate geometry, 30Plate height, 30Plate stacker, 6Plate width, 30Plates

defining, 24deleting, 25existing names, 24loading, 37manufacturer, 24placing on loading tray, 26, 29positive/negative, 25release jammed plate, 37sensitivity, 25thickness, 25unloading, 49

Platesetteronline view, 20shutdown, 9

Positive plate, 25Preferences, 19Pre-heat oven, 6

Index

54 Lotem 400 Family User Guide

Press Formatson PC controller, 30

Problems, 49Process time indication, 20Processor, 6Progress indicator, 20

RReady status, 14Rear door, 4Res. Int. Table, 25Reset button, 40Reset machine, 16Right side door, 3Routine Functions, 15

SSafety interlocks, 20Save Plate, 25Scale markers, plate, 26, 29Sensitivity, 25Service mode, 15Service status, 14, 20Setting, 19Start up status, 14Status indicator, 14Stop button, 19

TTail grippers, 38Tail margin, 30

See also Margins

UUnits of measurement, 19User interface

features, 13main window, 13

User types, 18Utilities, 17

WWorking status, 14

Documents

Lotem 400 Family UG en JUN10