Operator Guide

NEWSmatic Systems
MAKO 4matic Systems

AO45200
Revision 2
 Operator Guide
MAKO 4matic and NEWSmatic Systems

This guide reflects the systems as September 2006

© copyright ECRM Incorporated 2006

For additional copies of this manual contact:

ECRM Order Processing

554 Clark Road
Tewksbury, MA 01876
www.ecrm.com

Phone No. (US) - (+1) 978-851-0207 — Fax (US) - (+1) 978-851-7016

Phone No. (UK) - (+44) 1923-218255 — Fax (UK) (+44) 1923-218256
Phone No. (Hong Kong) - (+852) 2-564-8989
Fax (Hong Kong) (+852) 2-564-8821

Proprietary Notice

The information in this publication is the sole property of ECRM. It

cannot be reproduced, in whole or in part, without the express written
consent of ECRM. The information is believed to be accurate as of the
publication date, but it is subject to change without notice due to
continuing product development.

ECRM®, NEWSmatic CTP®, and 4matic CTP® are trademarks of

ECRM Imaging Systems. Other brand and product names are
trademarks or registered trademarks of their respective owners.

ii AG45200 Rev. 2
 Table of Contents
Preface 1
Scope of this Guide 1
Conventions used in this Guide 1
Instructions 1
Model-specific Information 1

Requirements and Safety 1

Introduction to the System 1
System Requirements 1
System Power and Heat Dissipation 1
Environmental Requirements 1
Air Requirements 1
Laser Safety 2
Laser Product Classification 2
Regulatory Information 2
Electromagnetic Emissions 2
Identification and Certification Label (ratings plate) 3

System Operation 5
Introduction 5
Identifying Your System 6
System Parts 7
Platesetter 7
Registration Pin Bars 10
60-Plate Cassette and Cart 10
250-Plate Cassette w/Integrated Cart 13
Workstation 16
CtServer Software 16
Power Conditioner 16
Starting Up the System 17
Running Jobs 17

AG45200 Rev.2 iii

Shutting Down the System 19
Using the Control Panel 20
Keys 20
LEDs 21
Menu Selection 22
User Preferences Menu 23
User Maintenance Menu 31
Test Patterns Menu 34
Running a Step Wedge Exposure Test 38
About the Step Wedge Test 38
Preparing a Plate for the Test 39
Running the Step Wedge Test Pattern 40
Evaluating the Output 42
Other Exposure Tests 43
Equipment Configuration Displays 44
Status Messages 45
Error Messages 46
Operator-Correctable Errors 46
Correcting Errors 48
Removing and Replacing Covers 48
Autoloader Covers 49
Transport Cover 50

Media Handling 51
Introduction 51
Safety Precautions 52
Media Supply Reporting 52
Media Types and Sizes 53
Installing and Removing a Pin Bar 54
Installing a Pin Bar 55
Removing a Pin Bar 56
Mounting a 60-Plate Cassette on the Cart 57
Mounting the Cassette 57
Dismounting the Cassette 58
Loading a 60-plate PSS Cassette 59
Opening the Cassette 59
Adjusting the Alignment Pins 61

iv AG45200 Rev.2
 Loading Plates into the Cassette 64
Loading an SSR Cassette (60- or 250-plate) 66
Opening the Cassette 66
Adjusting the Alignment Pins 68
Loading Plates into the Cassette 70
Loading the Cassette into the Autoloader 73
Refilling the Cassette when Plates Run Out 75
Refilling the Cassette with the Same Type of Plate 75
Refilling the Cassette with a Different Type of Plate 77
Topping Off the Cassette Supply 78
Defining and Loading a New Plate Type 80
Manually Loading a Plate 82
Emptying the Slip Sheet Disposal Bin 84
Bin Counter 84
Emptying the Bin 85
The Slip Sheet Compactor 86
Emptying the Chad Container 87

Maintenance and Troubleshooting 89

Introduction 89
Cleaning the System 89
Pin Bar 91
Platesetter Exterior 91
Vacuum Cups 91
Fan Filters 92
Transport Fan Filters 93
Front (Input) Rollers 95
Output Rollers 96
Plate Cassette 96
Media Transport Output Sensor 97
Media Transport Belt (24”-wide Belt) 97
Ionizer Bar 98
Lubricating the System 98
Pickup Assembly 100
Pinch Roller Cams and Wear Pads 101
Pickup Assembly Rail 101
Clearing Misfeeds 102

AG45200 Rev.2 v
Manually Lowering the Cassette Platform 102
Aligning the Platesetter and the Processor 103
Leveling the On-line Processor 104
Leveling the Platesetter 104
Leveling the Cassette Assembly 106
Adjusting the Height of the Cassette 107
Checking the Mist Separator 108

vi AG45200 Rev.2
Preface
Scope of this Guide
This guide explains how to operate and maintain MAKO 4matic
and NEWSmatic platesetters. It covers all aspects of operation,
from the loading of media to the delivery of exposed media to an
on-line processor.
All MAKO 4matics and NEWSmatics use a Class 3B laser. This
guide includes safety and regulatory information about the laser. Be
sure to read this information before operating the system.
This guide assumes the system is properly installed and plugged
into the AC mains, and that the system has been calibrated and
tested for proper operation and acceptable output.

Conventions used in this Guide

Instructions
A “press” instruction always refers to a platesetter control panel
key. For example, “press MENU” is an instruction to press the
control panel MENU key.
A “click” instruction always refers to a CtServer program button
or icon. For example, “click RESUME OUTPUT” is an instruction
to click on the CtServer RESUME OUTPUT button.

Model-specific Information
Except where otherwise noted, all information presented in this
manual pertains to any NEWSmatic or 4matic model. Likewise,
except where otherwise noted, the terms “the platesetter” and “the
system” pertain to any NEWSmatic or 4matic system.

AG45200 Rev. 2 vii

viii AG45200 Rev. 2
Requirements
and Safety
1
Introduction to the System
The system includes a platesetter, a plate cassette and cart, a control
workstation, CtServer software, and a power conditioner.
The cassette must be loaded in a safe-light environment. Refer to
your plate manufacturer’s specifications for safe-light
requirements.

System Requirements
System Power and Heat Dissipation
Power 100 - 240 Volts; 3 Amps;
250 Watt maximum;
50/60Hz, single phase.
Heat Dissipation 850 BTU/hour

Environmental Requirements
Temperature- 62 - 86 degrees F (17 - 30 degrees C)
Humidity 45 - 65%, non-condensing.
Note: Operating the system outside of the ranges specified above
may affect performance.

Air Requirements
5BAR@283 liters/min (10 CFM @ 75 PSI)

AG45200 Rev. 2 1
Laser Safety
Laser Product Classification
The system is classified as a Class one (I) laser product that
contains a Class 3B (IIIb) laser System. This classification means
that the operator is exposed to no hazardous laser light during
operation and maintenance. The laser itself, however, is a Class 3B
(IIIb) laser device, and emits visible laser light which 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.

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

2 AG45200 Rev. 2
 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 correct the interference at his or her
own expense.
Compliance with applicable regulations depends on the use of
shielded cables, which the user may be responsible for procuring.

Identification and Certification Label (ratings plate)

The identification and certification label (Figure 1 - 1) is attached to
the pedestal of the platesetter unit, near the power entry receptacle.

AG45200 Rev. 2 3
 Figure 1 - 1 Identification and Certification Label

4 AG45200 Rev. 2
System
Operation
2
Introduction
This chapter describes the system and provides general operating
instructions. The material is organized as follows:

• “Identifying Your System” on page 6

• “Starting Up the System” on page 11
• “Shutting Down the System” on page 13
• “Using the Control Panel” on page 20
• “User Preferences Menu” on page 23
• “User Maintenance Menu” on page 19
• “Test Patterns Menu” on page 29
• “Running a Step Wedge Exposure Test” on page 38
• “Other Exposure Tests” on page 43
• “Equipment Configuration Displays” on page 44
• “Status Messages” on page 45
• “Error Messages” on page 44
• “Removing and Replacing Covers” on page 48

AG45200 Rev. 2 5
Identifying Your System
To use the information that follows, you need to know which
NEWSmatic or 4matic system you are operating and what options,
if any, it includes. Compare the features of your system to those
described below to determine which system and options you have.
Table 2-1: SYSTEMS AND OPTIONS
System Distinguishing Features
60-Plate Uses a 3.5”-deep cassette that has permanent slip sheets
Permanent Slip Sheet mounted inside. Plates are loaded in one at a time. A
(PSS) System separate cart provides for transporting the cassette.
Uses a 3.5”-deep cassette that does NOT have perma-
60-Plate nent slip sheets. Plates are loaded in a stack at a time,
Slip Sheet Removal without removing the plate manufacturer’s paper slip
(SSR) sheets (interleaf sheets). The system automatically
System removes the sheets and deposits them in the bin. A sep-
arate cart provides for transporting the cassette.
Uses a 5”-deep cassette that does NOT have permanent
250-Plate slip sheets. Plates are loaded in a stack at a time, with-
Slip Sheet Removal out removing the plate manufacturer’s paper slip sheets
(SSR) (interleaf sheets). The system automatically removes
System the sheets and deposits them in a bin in the base. The
cassette has its own integrated cart.
Option Distinguishing Features
A 4-element punch unit, mounted inside the imaging
Plate Punch unit, on the left side, between the output roller and the
media transport.
The compactor is a mechanical device that is mounted
Slip Sheet Compactor inside the disposal bin. It includes two large arms and a
large flattening plate that periodically descend to com-
press the slip sheets inside the bin.

The model number and serial number for your system is specified
on an label that is near the AC power receptacle at the back of the
system. (See "Identification and Certification Label" on page 4.)

6 AG45200 Rev. 2
System Parts
Your system includes a platesetter, two registration pin bars, a plate
cassette and cart, a control workstation, a power conditioner, and
CtServer software.

Platesetter
The platesetter includes an autoloader, an imaging unit, and a media
transport.

Autoloader
The autoloader picks up the top plate in the cassette,
positions it in front of the imaging unit, registers it, and then
guides the plate into the imaging unit. Additionally, in
models that support automatic slip sheet removal (SSR), the
autoloader also automatically removes and discards the
interleaf slip sheets.
The autoloader has three removable covers. They are
removed to change the registration pin bar, manually load a
plate, or perform maintenance and troubleshooting
operations. For details, see “Removing and Replacing
Covers” on page 48.

Imaging Unit
The imaging unit images the plate and then moves it to the
media transport unit. There are no operator-serviceable
parts in the imaging unit, so it has fixed covers.

Media Transport
The media transport moves the imaged plate to a customer-
supplied plate processor.
Two versions of the media transport are in production. One
has a 24-inch wide conveyor belt, and the other has two
narrow drive belts and an array of rollers. Except for having

AG45200 Rev. 2 7
 slightly different cleaning and lubrication requirements,
both versions are the same from an operator’s standpoint.
The unit has a removable top cover for performing routine
maintenance and troubleshooting. For more, see
“Removing and Replacing Covers” on page 48.

IMAGING
UNIT
MEDIA
AUTOLOADER TRANSPORT
PLATE
CASSETTE
WITH CART

PLATESETTER REGISTRATION
PIN BARS

CT SERVER CONTROL POWER

SOFTWARE WORKSTATION* CONDITIONER

* THE MONITOR IS ORDERED AS AN OPTION

Figure 2-1 Complete System

8 AG45200 Rev. 2
 Other Platesetter Parts
Power Switch

The power switch is on the left side, under the media

transport (see Figure 2 - 2.) Pressing zero (0) turns OFF
power to the platesetter; pressing one (1) turns ON power.
Note: The power switch controls dc power to the platesetter, not
ac power. To remove ac power, unplug the ac power cord
from the platesetter or from the power conditioner outlet.
WARNING
LIGHT
CONTROL
PANEL

POWER
SWITCH

Figure 2 - 2 Platesetter Parts

Power Cord Receptacle

The power cord receptacle is located beside the power

switch.
The platesetter, the CtServer computer, and the computer
monitor must all be plugged into the system power
conditioner (see page 16). If all three devices are not
plugged into the power conditioner, damage resulting from
voltage spikes, brownouts, etc., will NOT be covered by the
warranty.
Control Panel

The control panel allows the operator to interact with the

platesetter. Many platesetter operating parameters are set up
and controlled via the control panel.

AG45200 Rev. 2 9
 Warning Light on Top of Unit

The warning light (see Figure 2 - 2 on page 9) comes on

when the system requires operator intervention. The light
flashes when an error exists, when plates run out, or when
the plateline interface halts the system for an extended
period. The light stays steady on when the plate supply is
low.
Note: A second, remote warning light that can be positioned up to
50' (15.25 meters) away from the platesetter is available as
an option.
Plate Punch

Some platesetters are equipped with a plate punch. The

punch is located inside the imaging unit, on the left side,
between the output roller and the media transport.
Operating parameters for the punch are set up in CtServer.
The only punch-related task an operator performs is to
periodically empty the chad container. See “The Slip Sheet
Compactor” on page 86.

Registration Pin Bars

Two registration system pin bars come with every system.
One is for short plates (less than 19.5 inches/49.53 cm
long); the other is for long plates (19.5 to 36.5 inches /
49.53 to 92.7 cm long). Section 3 explains how to remove
and replace a pin bar.

60-Plate Cassette and Cart

There are two types of 60- Note: If your system uses a 250-
plate cassettes. One type plate cassette, skip this section and
has permanent slip sheets, refer to the section entitled "250-
and the other does not. Plate Cassette w/Integrated Cart"

10 AG45200 Rev. 2
 60-Plate Cassette with Permanent Slip Sheets
If your platesetter is NOT equipped with an automatic
slip sheet removal system, your cassette has permanent
slip sheets. With this cassette, you must load the plates into
the cassette one at a time. For each plate, you must: (a)
remove the manufacturer’s slip sheet, (b) set the plate in the
cassette, and (c) place one permanent slip sheet over the
plate.
There are two versions of the cassette with permanent slip
sheets. The low-capacity version has 25 slip sheets and
holds up to 25 plates. The high-capacity version has 60 slip
sheets and holds up to 60 plates.

60-Plate Cassette without Permanent Slip Sheets

If your platesetter is equipped with a slip sheet removal
(SSR) system, your cassette does not have permanent
slip sheets. You can load a stack of new plates into the
cassette straight out of the box, without removing the
slip sheets the manufacturer placed between plates.
Cardboard sheets that plate manufacturer places at the top
and bottom of the stack of plates must be removed.

Working with a 60-Plate Cassette and the Cart

Cassettes must be loaded in a safelight environment.
Typically, loading is performed with the cassette mounted
on the cassette cart.
After the cassette is loaded, it is inserted into the autoloader.
Then, the cassette light shield is pulled back (opened),
which makes the plates accessible to the pickup arm
assembly.
When the platesetter is sent a job, the pickup arm assembly
picks up the top plate in the cassette, positions the plate in

AG45200 Rev. 2 11
 front of the imaging unit, registers the plate, and then moves
the plate into the input rollers, which subsequently drive the
plate into the imaging unit.
The autoloader includes an automatic lock that prevents
removal of the cassette at inappropriate times. The lock
operates in conjunction with optical sensors that monitor
the insertion and removal of the cassette and the opening
and closing of the light shield. The opening and closing of
the lock is controlled by the Change Plate command in
CtServer.
A separate, stand-alone cart is used to transport 60-plate
cassettes from one location to another.
The reflective REFLECTIVE LIGHT SHIELD
dot on the right DOT
side of the LABEL
cassette light
shield triggers
the optical
sensor that
detects the
opening and
closing of the CASSETTE
light shield
Note: When a cas-
sette is in the CART
platesetter, it is
good practice Figure 2 - 3 60-Plate Cassette
to close and
lock the cassette light shield if the system is to remain idle
for an extended period of time (overnight).
The label at the front of the cassette can be used to identify
the plate that is in the cassette.
Some 60-plate cassettes have a cassette ID block mounted
on the light shield. For more about the ID block — which is
also used on 250-plate cassettes — see page 15.

12 AG45200 Rev. 2
 250-Plate Cassette w/Integrated Cart
The 250-plate cassette assembly is Note: If you use a 60-plate cassette,
comprised of a cassette mounted skip this section and refer to the
atop an integrated cart. section entitled "60-Plate Cassette
and Cart" on page 10.
The cassette has movable platform
base. When a cassette is inserted in the autoloader, four arms in the
motorized cassette platform lift assembly come up and contact the
underside of the base. Then, depending on the number of plates in
the cassette, the lift assembly pushes the base up until the top plate
in the cassette is at a prescribed distance from the pick-up
mechanism. As jobs are processed, the lift assembly continually
makes small, incremental platform height adjustments to keep the
top plate in the cassette at a constant height relative to the pick-up
mechanism.
IMAGING
AUTOLOADER UNIT
CASSETTE UNIT
PLATFORM TRANSPORT
LIFT ASSEMBLY UNIT

250-PLATE
CASSETTE

PLATESETTER

CASSETTE DISPOSAL
ASSEMBLY
ASSEMBLY BIN DOOR
INTEGRATED
CART

Figure 2 - 4 250-Plate System

When the platform is bottomed out, the storage compartment is

approximately 3-1/2” (89 mm) deep and can hold up to 250 12-mil

AG45200 Rev. 2 13
 plates with 2-1/2-mil thick slip sheets. The table that follows shows
the plate capacity of the cassette for popular plate thicknesses.

Table 2-2: 250-Plate Cassette,

Capacities for Different Plate Thicknesses
Advertised Nominal Nominal Combined
Cassette Plate
Plate Plate Slip Sheet Nominal
Capacity*
Thickness Thickness Thickness Thicknesses
14 mil .0135” .0025” .016” 210
12 mil .0115” .0025” .014” 250
8 mil .0075” .0025” .010” 330
6 mil .0055” .0025” .008” 410
* Nominal capacity. Capacity varies depending on the actual thickness of the plates
and the slip sheets, temperature, humidity, and other environmental variables.

When 250 maximum size plates (25” x 36-1/2” / 635 mm x 927

mm) are in the cassette, it weighs approximately 420 lbs (191 kg).
The cassette must be loaded in a safelight environment.
After plates are loaded, the cassette is rolled to the platesetter and
docked in the autoloader. Once the cassette is docked and locked in
place, the cassette light shield is pulled back (opened), making the
plates in the cassette accessible to the pickup arm assembly.
When the platesetter receives a job, the pickup assembly picks up
the top plate in the cassette, moves it to input shelf, registers it, and
guides it into the imaging unit. The plate is then imaged. After
imaging, the plate moves onto media transport, which moves the
plate into the plate processor.
The autoloader has an automatic lock that prevents removal of the
cassette at inappropriate times. The lock works with optical sensors
that monitor the insertion and removal of the cassette and the
opening and closing of the light shield. The opening and closing of
the lock is controlled via the Change Plate command in CtServer.

14 AG45200 Rev. 2
 The reflective dot on the right side of the cassette light shield (see
below) triggers the optical sensor that detects the opening and
closing of the light shield.
ID BLOCK ALIGNMENT REFLECTIVE
ARROW DOT
LIGHT
SHIELD
LABEL

CASSETTE
CART

Figure 2 - 5 250-Plate Cassette

Note: When a cassette is in the platesetter, it is good practice to
close and lock the light shield if the system is to remain idle
for an extended period of time (for example, overnight).
The label at the front of the cassette can be filled in to identify the
plate the cassette holds. The alignment arrow is an aid for aligning
the cassette with lift mechanism, which also has alignment arrows.
The ID block on the cassette can be coded with a unique
identification number the platesetter will recognize when the “USE
CASSETTE IDs” option is enabled. For more, see “USE
CASSETTE ID’s” on page 27.
Note: The ID block sup-
ports identification of up Scheme 1 Scheme 5
to 8 different cassettes,
Scheme 2 Scheme 6
where each cassette is
configured with one of the Scheme 3 Scheme 7
coding schemes shown at
the right. Scheme 4 Scheme 8

Figure 2 - 6 Cassette ID Coding

AG45200 Rev. 2 15
 Workstation
The control workstation connects directly to the platesetter and
runs the CtServer software. The operator makes frequent use of the
workstation, so it should be set up next to the platesetter.

CtServer Software
CtServer is used to send jobs to the platesetter and define the plate
and pin bar requirements for jobs. Detailed instructions for using
CtServer are presented in CtServer for MAKO CTP Systems Guide
AG45199, which is included on the CtServer CD.

Power Conditioner
The power conditioner protects the system against power quality
problems like brownouts, surges, over-voltage, sags, and line noise.
The platesetter, the workstation, and the monitor all must be
plugged into the power conditioner.
NEWSmatic / MAKO 4matic System

AC MAINS
POWER
CONDITIONER
AC INLET
AC Power
AC OUTLETS

AC Power
AC Power
AC Power

AC INLET RS-232* AC INLET AC INLET

SCSI Monitor
PROCESSOR PLATESETTER Plate Line IF PC MONITOR
(CtServer)

* Used by service personnel to run diagnostic programs.

Figure 2 - 7 AC Power and I/O Connections

16 AG45200 Rev. 2
Starting Up the System
Step 1. Begin by powering up the platesetter.
The power switch is located on the rear left side of the
machine (see Figure 2 - 2 on page 9). Depress one (1)
to turn the power ON. When the system completes its
initialization, a four-line message like the one shown
below appears on the control panel display:
ONLINE
.............
..............
[status of the plate supply] [slip sheet bin contents]

Step 2. When the ONLINE message displays, power up the

control workstation.
Step 3. After workstation boots up, launch CtServer. Once it is
running and the platesetter is ONLINE, the system is
ready to expose images.
Note: It is recommended that the platesetter be powered on for a 1-
hour warm-up period prior to imaging.

Running Jobs
The following is an summary of the how to bring up the system and
run a series of jobs. The presentation assumes a plate cassette is
installed in the platesetter.

Step 1. Start up the system as explained in the preceding

section.
Step 2. In CtServer, select a plate type.
Step 3. If prompts appear on the control panel display, follow
the prompts.

AG45200 Rev. 2 17
 Step 4. Wait for the control panel to display the following mes-
sage:
ONLINE
[PIN BAR NAME]
[PLATE TYPE NAME]
[status of the plate supply] [slip sheet bin contents]

Step 5. Make sure the displayed pin bar is installed in the

machine, and the displayed plate type is loaded in the
cassette.
Step 6. Check the label on the plate cassette to make sure it con-
tains the correct plate for the jobs to be submitted.
Step 7. Submit the job(s) to the platesetter.
Step 8. In CtServer, monitor the plate supply as jobs run.
a) When the supply runs low, pause job output,
select the ‘Change Media’ function and plate,
and reload the cassette.
b) When the supply runs out, select the plate in the
Change Media dialog and reload the cassette.

Step 9. In a safelight environment, load a new batch of plates

into the cassette.
Step 10. Repeat steps 6 through 10 as required to continue run-
ning jobs.
Step 11. To run a batch of jobs that require a different plate:
a) In CtServer, pause output, select change media,
and select the new plate type from the PLATE
TYPE pull-down list.
b) Load a cassette with the new plate type into the
platesetter.
c) If the new plate type requires a different pin bar,
when prompted remove the installed pin bar
replace it with the new pin bar.
d) Resume output.

18 AG45200 Rev. 2
Shutting Down the System
To shut down the platesetter:

Step 1. Exit CtServer.

Step 2. If a job is in process, wait for the plate to clear the trans-
port and move into the processor.
Step 3. Depress the zero (0) side of the platesetter power switch.
Do this only when the display reads:
ONLINE
[PIN BAR NAME]
[PLATE TYPE NAME]
[status of the plate supply] [slip sheet bin contents]

Step 4. To shut down the workstation, invoke the shutdown

command and turn off power.
Note: Once the platesetter is turned off, the workstation must be
rebooted after the platesetter is turned back on in order to
establish communication.

Step 5. If the system is to be shut down for an extended period,

(for example, overnight), close and lock the cassette
light shield.

AG45200 Rev. 2 19
Using the Control Panel

LEDS
EXPOSE ATTENTION ERROR

DISPLAY
(4-LINE)

PREV NEXT OK

MENU SELECT CANCEL

KEYPAD

Figure 2 - 8 Control Panel

Here’s how the control panel keys and LEDs work when the
machine is operating in a menu state.

Keys
Toggles the system between MENU selection state and
MENU
ONLINE state.
PREV
Moves you backward through the menu or moves the
cursor backward within the current menu item.

NEXT
Moves you forward through the menu or moves the cursor
forward within the current menu item.

20 AG45200 Rev. 2
 Scrolls through the options for the current menu item or
SELECT
increments the numeric digit under which the cursor is
positioned.
OK
In menu mode, from anywhere in a numeric field causes
the next menu item to display. At the last item of a menu,
causes a return to the first item of the menu.
In manual feed mode, starts exposing the loaded plate.
For prompts, confirms the operator has completed a
requested operation.

CANCEL
Cancels a pending “load plate/cassette” request, but does
not stop a job that is in progress.
The Emergency Stop button. Stops moving parts in the
platesetter.

LEDs
When flashing, the Green LED that indicates the plate is
EXPOSE being exposed. Additionally, indicates registration pin
contact when loading a plate.
When flashing, the Yellow LED that indicates there is a
ATTENTION condition that requires operator attention. The LCD display
indicates what needs to be done.
When on solid, indicates a low plate supply.
Red LED that indicates a platesetter error condition. The
ERROR LCD display indicates what the error is.

AG45200 Rev. 2 21
Menu Selection
There are three operator menus:
• User Preference Menu (See page 23).
• User Maintenance Menu (See page 31.)
• Test Pattern Menu (See page 34.)
To select, review, and set parameters in any menu:

Step 1. Press MENU to enter the user menu system.

Step 2. Press SELECT until the menu you want displays on the
LCD.
Step 3. Press NEXT to enter the menu.
Step 4. Set the parameter to what you want. Press SELECT to
change the value.
Step 5. Press Next to go to the next parameter until you have
completed your selections.
Step 6. Repeat steps 4 and 5 until all changes are made.
Step 7. Press MENU to exit the user menu system.

ONLINE
MENU

USER SELECT USER

TEST SELECT TEST SELECT
PREFERENCES MAINTENANCE
PATTERNS PATTERNS
PATTERNS
NEXT NEXT NEXT
USER MENUS

Figure 2 - 9 The User Menus

22 AG45200 Rev. 2
User Preferences Menu
This menu provides for changing operating parameters to suit your
personal preferences or meet special job requirements.
UNITS OF MEASURE
OPTIONS: ENGLISH (inches) or METRIC
(millimeters)
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.
IMAGE OFFSET
LIMITS: 0.300” to +0.300” (-7.62mm to +7.62mm)
The image may be shifted to the left with a negative (-)
value, or to the right with a positive (+) value by up to 0.300
inches. Press PREV to access the (+) and (-) sign.
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.

AG45200 Rev. 2 23
 ONLINE User Preferences
MENU

SELECT
USER SELECT USER SELECT TEST
PREFERENCES MAINTENANCE PATTERNS
NEXT

OVERLAP SLIP SHEET

UNITS OF OUTPUTTING
MEASURE SMALL/BIG
IMAGING LENGTH THRESHOLD
NEXT
NEXT NEXT NEXT

WARNING LEVEL
PROCESSOR BIG SLIP SHEETS
AUDIO ALERTS SPEED
IN BIN
NEXT NEXT NEXT

IMAGE ESTIMATED NUMBER WARNING LEVEL

OFFSET OF JOBS PER SMALL SLIP SHEETS
MONTH IN BIN
NEXT NEXT NEXT

PERIODIC MULTIPLE PLATE

ONLY 1 PIN BAR MAINTENANCE PICKUP ERROR
IN USE ALERTS SENSITIVITY
NEXT NEXT NEXT

IGNORE LASER ENABLE ENHANCED

CASSETTE LOCK PLATE
TEMP. ERRORS AFTER 5 SECONDS SEPARATION
NEXT NEXT NEXT

IGNORE MISSING USE

SLIPSHEET IN MONITOR DISPOSAL
CASSETTE CASSETTE ID’S BIN FULL
NEXT NEXT NEXT

USE TRANSPORT CASSETTE AND BIN ENABLE SLIP SHEET

AS OUTPUT TRAY CONTENT DISPLAY COMPACTING
NEXT NEXT NEXT
EXPOSE ATTENTION ERROR

USE PLATELINE SLIPSHEET ONLINE

INTERFACE THICKNESS
PREV NEXT OK

NEXT NEXT
MENU SELECT CANCEL

Figure 2 - 10 User Preferences Menu Map

24 AG45200 Rev. 2
 IGNORE LASER TEMPERATURE ERRORS
OPTIONS: YES or NO
If the laser exceeds its target operating temperature an error
will be reported. If this happens, the problem should be
fixed. However, if critical jobs need to be completed, it is
possible to operate the laser at a higher temperature by
selecting the “YES” option.
Note: Operating the laser at a higher temperature shortens the life
of the laser.
IGNORE MISSING SLIPSHEET IN CASSETTE
OPTIONS: YES or NO
Yes (the default setting) prevents the platesetter from
reporting an error if it fails to detect a slip sheet on the top
plate in the cassette. No causes the platesetter to report an
error if it fails to detect a slipsheet on the top plate in the
cassette.
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.

AG45200 Rev. 2 25
 OVERLAP OUTPUTTING AND IMAGING
OPTIONS: YES or NO
If this option is set “YES,” an operator can begin imaging
another plate while the previous plate is moving to the
processor.
PROCESSOR SPEED
LIMITS: 9.5 inches per minute to 77.9 inches
(241 mm per minute to 1980 mm)
Should be set to match the speed of the online processor.
ESTIMATED NUMBER OF JOBS PER MONTH
LIMITS: 1 to 30000
Provides for entering the number of plates per month you
typically run. The platesetter uses the entry to calculate
when to display “Periodic Maintenance is Overdo”
messages on the control panel display.
PERIODIC MAINTENANCE ALERTS
OPTIONS: ENABLED or DISABLE
If this option is enabled, “Periodic Maintenance is Overdo”
messages will appear on the control display to prompt you
to perform overdo maintenance. If the option is disabled,
the messages will not appear.
The setting of the ESTIMATED NUMBER OF JOBS
PER MONTH option (above) governs the plate count /
time interval calculations the system performs to “know”
when to display the alert.

26 AG45200 Rev. 2
 ENABLE CASSETTE LOCK AFTER 5 SECONDS
OPTIONS: YES or NO
“YES” enables the cassette lock to automatically engage 5
seconds after the system first detects that the cassette is
being removed. “NO” prevents the lock from automatically
engaging after the system detects that the cassette is being
removed. “NO” keeps the lock open until the cassette is re-
inserted.
USE CASSETTE ID’s
OPTIONS: YES or NO
YES enables the platesetter to read an identification code on
the cassette. NO prevents the platesetter from reading the
code.
When YES is selected, the platesetter knows which cassette
it is working with, so the platesetter can do precise reporting
on the state of the media supply in the cassette.
When NO is selected, the platesetter does not know which
cassette is in the autoloader, so the platesetter does more
approximate reporting on the state of the media supply in
the cassette.
It takes the platesetter takes about 10 seconds to capture the
cassette ID identification when the cassette is first installed.
CASSETTE AND BIN CONTENT DISPLAY
OPTIONS: COUNT, PERCENT, or BOTH
Sets the format used to display the content of the cassette
and the disposal bin.
“COUNT” selects a count
format. The figure at the right 28 146
shows a “COUNT” display. It
indicates 28 plates are in the cassette and 146 slip sheets are
in the bin.

AG45200 Rev. 2 27
 “PERCENT” selects a format in
which the content of the cassette 12% 60%
and bin are expressed as a
percentage. The figure at the right shows a
“PERCENTAGE” display. It indicates the cassette is 12%
full and the bin is 60% full.
“BOTH” causes both
formats to be displayed. 28,12% 146,60%
Note: For more about media sup-
ply reporting, see page 52.
SLIP SHEET THICKNESS
LIMITS: 2.0 to 4.0 mils
Sets the slip sheet thickness value the platesetter uses to
calculate the height of the media supply in the cassette. The
default setting is 2.5 mils, which is a nominal slip sheet
thickness. If you are using thicker or thinner slip sheets, you
may find it necessary to increase or decrease the value
setting.
Note: The closer the slip sheet thickness setting matches the
actual thickness of the slip sheets in the cassette, the better
the accuracy of the media supply reporting.
SLIP SHEET SMALL/BIG LENGTH THRESHOLD
LIMITS: 9.843 inches to 47.50 inches
(250 mm to 1208 mm)
Sets the threshold value the system uses to determine if the
slip sheet going into the bin is “big” or “small.” For
example, if this option is set for 14.60”, the system to
recognizes a slip sheet shorter than 14.60” as being “small,”
and 14.60” or longer as being “big.”

28 AG45200 Rev. 2
 WARNING LEVEL FOR BIG SLIP SHEETS IN BIN
LIMITS: 1 to 9999
Defines the “big” slip sheet bin count that triggers control
panel prompts to empty the bin. For example, if this option
is set to 59, when the “big” slip sheet bin count reaches 59,
prompts to empty the bin will appear on the control panel
display the next time you change the cassette or the pin bar.
Note: If big and small plates are being mixed, the system monitors
the big and small slip sheets counts and decides when to
display a prompt to empty the bin.
WARNING LEVEL FOR SMALL SLIP SHEETS IN
BIN
LIMITS: 1 to 9999
Defines the “small” slip sheet bin count that triggers control
panel prompts to empty the bin. For example, if this option
is set to 258, when the “small” slip sheet bin count reaches
258, prompts to empty the bin will appear on the control
panel display the next time you change the cassette or the
pin bar.
MULTIPLE PLATE PICKUP ERROR SENSITIVITY
LIMITS: - 99 to +99
This option allows you to increase or decrease the sensitiv-
ity of the system the platesetter uses to report a possible
multiple plate pickup error. The default setting is zero.
Entering a positive number makes the system more sensi-
tive, and entering a negative number makes it less sensitive.
Note: Increasing the sensitivity increases the risk of the system
reporting false multiple plate pickup errors. Decreasing the
sensitivity reduces the risk of false multiple plate pickup
errors, but it also reduces the system’s ability to report an
actual multiple plate pickup.

AG45200 Rev. 2 29
 ENHANCED PLATE SEPARATION
OPTIONS: ENABLED or DISABLED
Controls the way the pickup mechanism removes plates
from the cassette.
ENABLED selects a pickup method specifically designed
to prevent multiple plate pickups. Select ENABLED if you
are working with a “sticky” batch of plates that do not
separate easily. Otherwise, choose DISABLED.
MONITOR DISPOSAL BIN FULL
OPTIONS: YES or NO
YES, the default setting, causes the platesetter to check for
a “bin full” condition every time a slip sheet of any size is
fed into the bin.
NO delays repeated checking for a “bin full condition” until
60 slip sheets have been fed into the bin.
ENABLE SLIP SHEET COMPACTING
OPTIONS: YES or NO
YES, the default setting, configures the platesetter to
operate normally with the compactor. NO configures the
platesetter to ignore the compactor and operate as if it were
not present.
Select NO if the compactor malfunctions and you need to
keep running plates while waiting for service. Otherwise,
keep this option set for YES.

30 AG45200 Rev. 2
User Maintenance Menu
This menu provides for reviewing technical information about the
system and/or exercising different machine functions.
PROGRAM VERSIONS
This option displays version numbers of the installed
software and firmware, which are displayed as:
CONTROLLER nnnnnn
JP0020 n.n JA1126 n
JA1142 n
“NEXT” TO CONTINUE

Where CONTROLLER nnnnnn is the part number of the

main controller board, JP0020 n.n is the part number and
revision level of the controller software, JA1126 n is the
part number and revision level of the controller firmware,
and JA1142 n is the part number and revision level of the
autoloader controller firmware.
RUN TRANSPORT
This option runs 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.
ENABLE USER ACCESS
This option disables the autoloader cover interlocks to
permit removal of the covers to perform maintenance or
troubleshooting.
This option can also be used to release the cassette lock
when CtServer is not running

AG45200 Rev. 2 31
 ONLINE
User Maintenance
MENU

SELECT SELECT SELECT

USER USER TEST
PREFERENCES MAINTENANCE PATTERNS
NEXT

To
PROGRAM NEXT To access T date
TO
T ACCESS
VERSION THE DATA
To

SELECT

RUN NEXT
TO EXERCISE
TRANSPORT THE FUNCTION
SELECT

RUN MEDIA NEXT

TO EXERCISE
ROLLERS THE FUNCTION
SELECT

ENABLE NEXT
USER ACCESS TO EXERCISE
THE FUNCTION
SELECT

PERIODIC NEXT
MAINTENANCE TO EXERCISE
THE FUNCTION
SELECT

DISPLAY NEXT
ERROR LOG TO ACCESS
EXPOSE ATTENTION ERROR
THE DATA
SELECT

DISPLAY NEXT PREV NEXT OK

LASER LOG TO ACCESS

THE DATA CANCEL
MENU SELECT

SELECT

Figure 2 - 11 User Maintenance Menu Map

32 AG45200 Rev. 2
 PERIODIC MAINTENANCE
This option allows you to review how many plates/days
remain before the next 1-month, 3-month, 6-month, and 12-
month maintenance is due.
USER MAINTENANCE 1-MONTH SUB MENUS
MENU
1 MONTH MAINTENANCE
IS DUE IN
XXX PLATES OR XXX DAYS SELECT RESET 1 MONTH COUNTER
'NEXT’ TO CONTINUE ARE YOU SURE?
NEXT OR YES/NO
PERIODIC 1 MONTH MAINTENANCE NEXT
MAINTENANCE IS PAST DUE
'NEXT’ TO CONTINUE
'SELECT’ TO RESET COUNTER
SELECT
NEXT

USER MAINTENANCE
MENU
3-MONTH SUB MENUS
NEXT

6-MONTH SUB MENUS

NEXT

6-MONTH SUB MENUS

NEXT

Figure 2 - 12

The option also allows you to start new 1-month, 3-month,

6-month, and 12-month maintenance tracking after you
perform the maintenance.
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
Displays status information about the system laser. The
information is useful to service personnel, who sometime
request the information over the phone during service calls.

AG45200 Rev. 2 33
Test Patterns Menu
This menu is for selecting test patterns and configuring test-related
operating parameters. Depending on which test pattern is selected,
some of the following options may be enabled and display, whereas
others may not.
TEST PATTERN MODE
OPTIONS: Enabled or Disabled
This option moves the system in and out of test pattern
mode.
TEST PATTERN TYPE
OPTIONS: List of Test Patterns (refer to Figure 2 -
13)
Test Patterns are for the use of qualified technicians only.
NUMBER OF PLATES
OPTIONS: 0 to 60
This option allows you to define the number of plates that
constitute a “full” cassette. For example, if you load the
cassette with 50 plates, set the option for “50.”
REVERSE IMAGE POLARITY
OPTIONS: YES or NO
This option will reverse the test pattern images. YES will
expose the background of the plate. NO exposes the image
area.
BAR WIDTH
OPTIONS: 1 to 999999 Pixels
This parameter specifies the width of the lines in the Bar
Test Patterns.

34 AG45200 Rev. 2
 Test Patterns
ONLINE
MENU

USER SELECT
USER SELECT
TEST SELECT

PREFERENCES MAINTENANCE PATTERNS

NEXT SELECT TEST

ENABLE PATTERN
MODE
SELECT

TEST PATTERN NUMBER OF

SELECTION OPTIONS PLATES DISABLE
NEXT
BARS (HORIZONTAL)
BARS (VERTICAL) REVERSE IMAGE
CHECKERBOARD PLATE THICKNESS
POLARITY
GRID NEXT
DROOP (MEDIA) NEXT
DROOP (SCOPE)
LASER PLATE WIDTH
RUN CONTINUOUSLY BAR WIDTH
only apply to the BARS test patterns

STEP WEDGE* NEXT

NEXT

Press SELECT to scroll PLATE LENGTH

through the selection options. BAR SPACING
When the desired test appears NEXT
(e.g. “Checkerboard”), press NEXT
NEXT to set up parameters for MAGNIFICATION
running that test. IMAGE (HOR)
LENGTH NEXT
* See “Running a Step Wedge
NEXT
Exposure Test” on page 38.
MAGNIFICATION
NEXT IMAGE (VER)
OFFSET
NEXT
NEXT

HORIZONTAL ONLINE
RESOLUTION
NEXT
VERTICAL
RESOLUTION EXPOSE ATTENTION ERROR

NEXT

EXPOSURE LEVEL
PREV NEXT OK

NEXT
MENU SELECT CANCEL

PLATE
SOURCE
NEXT

Figure 2 - 13 Test Patterns Menu

AG45200 Rev. 2 35
 BAR SPACING
OPTIONS: 1 to 999999 Pixels
This parameter specifies the width of the spaces between
the lines in the Bar Test Patterns.
IMAGE LENGTH
OPTIONS: 0.079 inches to 39.330 inches
(2 mm to 999 mm)
This parameter specifies the length of the test pattern to be
recorded.
IMAGE OFFSET (VERTICAL)
OPTIONS: 0.0000 inches to 39.330 inches
(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
MAKO 4matic OPTIONS
dpi: 1200, 1270, 1800, 2400, 2540, 3048, 3556
dpmm: 47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0

NEWSmatic OPTIONS
dpi: 1016, 1200, 1270, 1500, 1800, 2032, 2400, 2540
dpmm: 40.0, 47.2, 50.0, 59.1, 70.9, 80.0, 94.5, 100.0

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.

36 AG45200 Rev. 2
 VERTICAL RESOLUTION
MAKO 4matic OPTIONS
dpi: 1200, 1270, 1800, 2400, 2540, 3048, 3556
dpmm: 47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0

NEWSmatic OPTIONS
dpi: 1016, 1200, 1270, 1500, 1800, 2032, 2400, 2540
dpmm: 40.0, 47.2, 50.0, 59.1, 70.9, 80.0, 94.5, 100.0

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.
EXPOSURE LEVEL
LIMITS: 000 to 255
This menu entry sets the exposure level at the media. The
higher the number, the higher the exposure.
PLATE SOURCE
OPTIONS: Cassette or Manual
This option defines the plate loading method to be used.
PLATE THICKNESS
OPTIONS: 0.006 inches to 0.014 inches
0.15mm to 0.35mm
By picking a value, you set the plate thickness for test pat-
terns.
PLATE WIDTH
OPTIONS: 15.0722 inches to 25.078 inches
(382.9 mm to 636.9 mm)
By picking a value, you set the plate width for test patterns.

AG45200 Rev. 2 37
 PLATE LENGTH
OPTIONS: 11.322 inches to 36.578 inches
(287.6 mm to 929.1 mm)
By picking a value, you set the plate width for test patterns.
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.

Running a Step Wedge Exposure Test

About the Step Wedge Test
The step wedge test is used to calibrate the exposure setting to
match the plate and the processor chemistry. The test only applies
to photopolymer plates. The test involves taping a step-wedge test
strip on the plate, exposing the plate, and evaluating the resultant
test image as explained below.
Note: ECRM strongly recommends new processor chemistry be
used to process step-wedge test plates.
The figure below shows a step-wedge test strip. It happens to have
15 steps. Some test strips have fewer steps, and others have more.
On any given test strip, the first step is virtually clear, the last step

38 AG45200 Rev. 2
 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

15
11
1

10

12

13

14

15
11
1

9
Figure 2 - 14 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. 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

15
11
5
1

10

12

13

14

15
11
5
1

Figure 2 - 15 Typical Step-Wedge Test Plate Image

The distribution of dark steps, transition steps, and light steps varies
depending on the platesetter’s exposure setting, the plate type being
used, and the state of the processor chemistry.

Preparing a Plate for the Test

Step 1. Remove the cassette from the machine.
Step 2. In a safelight environment, open the cassette lid.
Step 3. Obtain a step wedge test strip.
Note: ECRM recommends using a Fuji 15-step “T” step wedge test
strip (ECRM PH0388) on Fuji plates, and a Stouffer 21-step
wedge (ECRM PH0389) on all other plates.

AG45200 Rev. 2 39
 Step 4. 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.
LEADING EDGE
OF PLATE

FRONT
OF
CASSETTE TAPE
STEP WEDGE
TEST STRIP
CENTERLINE OF PLATE
6 INCHES
15.2 CM

LEFT SIDE TAPE

OF
CASSETTE

Figure 2 - 16 Step Wedge Test Strip Placement

Step 5. Close and lock the cassette cover.

Step 6. Reload the cassette into the machine.
Step 7. Open the cassette light shield.

Running the Step Wedge Test Pattern

Note: This test can also be run from CtServer. Refer to the
CtServer for MAKO CTP Systems Guide AG45199 for
details.

Step 1. At the control panel, press MENU and then repeatedly

press SELECT until the “Test Patterns” Menu displays.
Step 2. Press NEXT, and then press SELECT to Enable.
Step 3. Press NEXT, and then repeatedly press SELECT until
the Step Wedge pattern displays. Then, press NEXT
again.

40 AG45200 Rev. 2
 Step 4. Set Horizontal resolution to the required resolution.
Step 5. Set Vertical resolution to the required resolution.
Step 6. Set Exposure to the value you wish to expose the wedge.
(The range is 0-255.)
Step 7. Set Plate Source to Cassette.
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.
Step 15. Making sure to maintain safelight conditions — which
may require using a large black cloth to cover the trans-
port unit — lift up the transport cover lid and remove
the taped-on step wedge.
Step 16. Replace the transport top cover.
Note: Note: In step wedge test pattern mode, the machine will not
beep or report cover interlock open messages.

Step 17. On the front panel, press OK. The transport feeds the
plate into the processor.
Step 18. Process the plate and evaluate the output.

AG45200 Rev. 2 41
 Evaluating the Output
Step 1. Refer to the
sidebar at the STEP WEDGE SCALE
right for 2
terms we will 3 3 No brush marks appear.
use later. Solid Step # may be visible.
4 4 Approximately 50%
Step 2. Examine your
test plate to Tail* exposure of area. Brush
5 5 marks visible.
see where the
Solid, Tail, Some minimal ghosting
and Clear 6 6 Clear may appear.
steps are
located. * Sometimes called Ghost or Scum, Tail steps
exhibit only partial exposure of the plate.
Step 3. Refer to
Table 2-3 on page 42 for exposure step wedge values
for several popular plate types. The values shown in the
table are for an ideal testing environment. Plate lot,
plate age, processing conditions, and processor chemis-
try 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.
Table 2-3: Step Wedge Values for Correct Exposure

Plate Plate Step Wedge Step Wedge Values

Manufacturer Product Name Test Strip when Exposure is Correct

Fuji LP-NV PH0388 Solid 3, Scum 4 or 5

KPG Violet Plate PH0389 Light tail 5
Agfa N91V PH0389 Solid 3, Scum 5

42 AG45200 Rev. 2
 Step 4. Figure 2 - 17 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 exposure setting and then run
another wedge test.

10

12

13

14

15
11
1

9
A

10

12

13

14

15
11
1

9
CORRECT EXPOSURE SETTING

10

12

13

14

15
11
1

9
B

10

12

13

14

15
11
1

9
EXPOSURE SETTING TOO HIGH

10

12

13

14

15
11
1

C
10

12

13

14

15
11
1

EXPOSURE SETTING TOO LOW

Figure 2 - 17 Evaluating Exposure Setting

Other Exposure Tests

The step-wedge test described above provides for adjusting focus
for a photopolymer plate, but not a silver plate.
For details about other tests that provide for adjusting focus for a
silver plate, refer to the CtServer for MAKO CTP Systems Guide
AG45199

AG45200 Rev. 2 43
Equipment Configuration Displays
These displays summarize the equipment configuration of the
system. The information they convey is intended for service
personnel. If you call for service, your service provider may ask
you to read the content of the displays to him over the phone,
before he goes to your site to service your system. To view the
displays:

Step 1. Place the system in ONLINE mode.

Step 2. Press the Select key. The first display appears.
Step 3. Press the Select key again. The second display appears.
Step 4. Press the Select key again. The last display appears.
Step 5. Convey the information on the LCD to your service pro-
vider.
Step 6. Press the select key to clear the display and return to
ONLINE mode
THE SCREENS DISPLAY THE FOLLOWING
ONLINE
INFORMATION ABOUT YOUR SYSTEM:
SELECT
MACHINE TYPE
SYSTEM CONTROLLER ID
CONFIGURATION FIRMWARE
DISPLAY 1
LASER POWER, FILM SENSITIVITY, OPTICAL EFFICIENCY
SELECT

SYSTEM
CONFIGURATION OUTPUT TYPE
DISPLAY 2 SPINNER MOTOR
SELECT

SYSTEM
CONFIGURATION TRANSPORT ENCODER
DISPLAY 3

SELECT

Figure 2 - 18 Configuration Displays

44 AG45200 Rev. 2
Status Messages
During operation, the control panel displays real-time information
about state of the system and/or of jobs in process. The following is
a list of frequently displayed status messages.
EJECTING PLATE - Exposing is complete and the plate is being
ejected onto the plate transport.
EXPOSING IMAGE - The system is now recording an image.
FEEDING PROCESSOR - Plate is on the transport and the leading
edge of the plate is moving into the processor.
FETCHING PLATE -A plate is being moved from the cassette to the
input shelf, where it will be registered.
INITIALIZING - The system is performing initialization functions
prior to going online.
MOVING TO PROCESSOR - Plate has been ejected from the
rollers and is moving to the processor.
ONLINE - The normal operating mode for the system.
PREPARING TO EXPOSE - The system is starting the spinner and
moving the plate to the recording start position.
REGISTERING PLATE - The plate is being registered and readied
for insertion into the imaging unit.
TEST PATTERNS - 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.
WAITING FOR LASER - The system is waiting for the laser to
reach operational temperature.
ATTENTION: PERIODIC MAINTENANCE IS OVERDUE - This
message appears during power up when the system determines
regular, periodic maintenance is overdue. If you see this message,
press MENU to invoke the User Maintenance Menu. Select the
Periodic Maintenance option, scroll through the displays to determine
which maintenance is needed, reset the tracking counters, shut down
the system, and then perform the required maintenance as explained
in Chapter 4.

AG45200 Rev. 2 45
Error Messages
During operation, error conditions may occur that require your
intervention. These messages will appear on the system display panel
and the error indicator LED will light. Additionally, if enabled, the
alarm will also sound.

Operator-Correctable Errors
CASSETTE IS MISSING - Means a cassette must be loaded into
the platesetter.
DISPOSAL BIN DOOR IS NOT SECURE - Means the slide door
to the slip sheet disposal bin must be closed.
TRANSPORT DOOR IS NOT SECURE - Means the transport lid
must be closed.
COVER IS NOT SECURE - This error is displayed when one of the
system covers (left, right, top, or autoloader) is not secure. Locate and
close the open cover, and then press OK.
OPERATOR ABORT - This error is displayed when the operator
aborts a job by pressing the STOP key.
LASER IS OVER TEMPERATURE - Alerts you that the laser is
over temperature. If you override this error in the User Preferences
Menu, the laser life will be shortened.
IMAGE OFFSET ERROR, INCOMPATIBLE PARAMETERS -
This error is displayed when the combination margin, resolution,
magnification, media width, and image offset result in a condition
where the image starts before the laser can activate. If you should
encounter this error, minor adjustments to the above parameters, to
push the image to the center of the plate should resolve the problem.
Note: In errors that follow, “U/D” is an abbreviation for Up/Down.
PICKUPCUP U/D: UNEXPECTED SENSOR - Something is
preventing the pickup mechanism from moving up or down as
expected. Possible plate out of position.
PICKUPCUP U/D: SLIP SHEET PICKUP FAILURE - A slip
sheets is being detected, but the mechanism is unable to grab it.
Possible slip sheet out of position.

46 AG45200 Rev. 2
 PICKUPCUP U/D: COULD NOT LIFT PLATE FROM
CASSETTE - Something is preventing the pickup mechanism from
lifting up the plate.
PLATE WAS NOT GRIPPED BY PICKUP CUPS - The Pickup
cups are not picking up the plate. (Typically, this error means the
pickup cups need to be adjusted.)
SLIP SHEET DID NOT REACH DISPOSAL ROLLER -
Something is preventing the slip sheet from feeding into the disposal
rollers. (Dirty rollers may be the cause. If so, clean them with
isopropyl alcohol.)
DISPOSAL BIN IS FULL - Displays when the disposal bin
overflows. Empty the bin and clear debris from the chute.
PLATE COULD NOT BE CLEARED FROM MACHINE -
Requires operator to clear media path.
IMAGER: SOMETHING UNEXPECTED IS ON INPUT SHELF
The sensors have detected something other than a plate on the input
shelf. Requires operator to clear plate path.
REGISTERING: PLATE DID NOT CONTACT PINS - Usually
caused by a disposal bin overflow. If so, empty the bin and clear
debris from the chute.
POSSIBLE MULTIPLE PLATE PICKUP - Sensor detected that
more than 1 plate may be on the input tray. Requires operator to clear.
SOMETHING UNEXPECTED IS ON THE REGISTERED
PLATE - The sensors have detected something other than a plate on
the input shelf. Requires operator to clear plate path.
LOADING PLATE: PLATE WAS LOST WHILE LIFTING
FROM THE CASSETTE - Plate separated from pickup cups. May
mean the pickup cups need to be cleaned or the cassette was not
loaded properly (e.g., a cardboard separator was loaded into cassette).
PICKUP ARM: COULD NOT MOVE TO DESIRED POSITION-
Something is preventing the pickup mechanism from moving forward
or backward. May mean the pickup arm is binding against a
misplaced plate or slip sheet.
PICKUP ARM: MOVEMENT TIMEOUT - Something is preventing
the pickup arm from moving at the expected speed. May mean the pickup
arm is binding against a misplaced plate or slip sheet.

AG45200 Rev. 2 47
 Correcting Errors
Step 1. In most cases, the system will display prompts that will
help you clear the error. Follow the prompts.
Step 2. If a plate is in the machine when the error occurs,
remove the plate and/or slip sheet as explained in the
Maintenance and Troubleshootingchapter at the end of
this manual.
Note: Occasionally the error may be caused by a poorly packaged
slip sheet. In this case, the cassette may have to be opened
(in safe lighting) and the slip sheet removed.

Step 3. Correct the condition that caused the error.

Step 4. Press the control panel OK button.
Step 5. Resume normal operation.

Removing and Replacing Covers

The platesetter has several removable covers (see Figure 2 - 19).
The covers are removed to change the pin bar, manually load a
plate, or perform troubleshooting and maintenance.
Note: The removable covers are interlocked. If you try to remove
one without first disabling the interlocks as explained in
other parts of this manual, the platesetter will halt operation
and issue an error report.

48 AG45200 Rev. 2
 FRONT AND REAR
AUTOLOADER MAIN COVERS
TOP COVER
AUTOLOADER TRANSPORT
SIDE COVER TOP COVER
(LEFT)

AUTOLOADER
SIDE COVER
CONTROL PANEL INTERLOCK (RIGHT)
COVER SWITCH
Figure 2 - 19 Removable Covers

Autoloader Covers
Top Cover
To remove the top cover:

Step 1. Grasp the hand holds.

Step 2. Lift the cover straight up and away from the platesetter.

To replace the cover:

Step 1. Carefully set it back in place.

Step 2. Make sure it mates with the control panel cover, the two
autoloader side covers, and the main cover. Also, make
sure that the metal flag on the underside of the cover
engages the interlock switch.

AG45200 Rev. 2 49
 Side Covers
To remove either side cover:

Step 1. Remove the top cover.

Step 2. Grasp the hand holds.
Step 3. Guide the cover straight up until it clears the platesetter
base pan.
Step 4. Draw the cover toward you and away from the machine.
To replace the cover:

Step 1. Carefully mate the sides of the cover with the control
panel cover and the front main cover.
Step 2. Mate the bottom of the cover with the channel in the
base pan.
Step 3. Push the cover down to snap it in place. As you do,
make sure metal flag on the inside of the cover engages
the interlock switch in the base pan.

Transport Cover
The transport has a removable top cover for performing
troubleshooting and maintenance.
To remove the cover:

Step 1. Grasp the hand holds.

Step 2. Lift the cover straight up and away from the back of the
platesetter.
To replace the cover:

Step 1. Set it back into position.

Step 2. Make sure the metal flag on the underside engages the
interlock switch.

50 AG45200 Rev. 2
Media Handling
Introduction
3
The system uses a cassette-based plate loading system. When the
cassette is in place, plates are automatically fed to the imaging unit
until the plate supply is exhausted. The system then prompts the
operator to change the cassette.
The system can handle a wide range of plate sizes (see “Media
Types and Sizes” on page 53). To insure accurate registration of all
supported sizes, two removable registration pin bars come with the
system. One is for smaller plates (up to 20 inches / 50.8 cm long)
and the other for longer plates (up to 36 inches / 91.4 cm long).
Replenishing the plate supply or switching to a new plate size and/
or pin bar requires using the CtServer software and the control
panel at the front of the platesetter. The basic steps are as follows:
Step 1. At the control workstation, in CtServer:
• Select the Change Media function.
• Select the appropriate plate type for the job you are about to
send to the platesetter.
• Select the feed method to be used (cassette or manual).
Step 2. Go to the platesetter control panel and perform actions
as directed by prompts that appear on the display.
Step 3. When prompted to do so, press the control panel OK
button to signal the platesetter that the correct plate size
and pin bar are in place.
Step 4. Go back to the control workstation. In CtServer, click
the RESUME OUTPUT button. The system resumes
imaging.
Note: Instructions for using CtServer are provided in the CtServer
Operator’s Guide, which is on the software CD.

AG45200 Rev. 2 51
Safety Precautions
The cassette can be very heavy. A fully loaded 250-plate cassette
weighs approximately 420 lbs. (191 kg) when loaded with two
hundred fifty 12-mil, 25” x 36.5” plates.
For safety sake, ALWAYS observe the following precautions when
handling media and/or loading cassettes:

• Enlist the help of an assistant to move a carton of plates weigh-

ing more than 40 lbs (18 kg).
• Enlist the help of an assistant to load a stack of plates weighing
more than 40 lbs (18 kg) into a cassette.
• Enlist the help of an assistant when loading large plates into a
cassette. (Larger plates tend to bend/crease more easily than
smaller plates.)
• Use the cassette cart to transport a loaded cassette from one
location to another.

Media Supply Reporting

The platesetter reports on the state of the media supply by
measuring the height of the stack of plates in the cassette and
calculating the number of plates that are in the stack.
The platesetter uses a nominal plate thickness value to calculate the
plate count. However, sometimes the actual thickness of the plates
in the stack differs from the nominal value the platesetter uses to
calculate the plate count. Furthermore, environmental factors like
temperature and humidity can affect the stack height. For these
reasons, the state of the media supply reported on the display is not
always exact.
When inexact reporting occurs, the margin of error is always
greatest when the cassette is first loaded into the platesetter, when
the stack of plates is highest. However, the margin of error gets
smaller as plates are used and the height of the stack decreases. By
the time the stack is down to 20% of its maximum height, the
margin of error becomes inconsequential.

52 AG45200 Rev. 2
Media Types and Sizes
The platesetter supports these media types and sizes:
Media Types - Violet-sensitive silver halide plates
Violet-sensitive photopolymer plates
Media Sizes -
Minimum 18.5” W x 11.4” L
(470mm x 290mm)
Maximum 25.00” W x 36.5” L
(635mm x 927mm)
Media thickness - 6 mil (0.15mm), 8 mil (0.20mm),
10 mil (0.25mm), 12 mil (0.30mm),
14 mil (0.35mm)
Configuration - Edge Registered

L = Length W = Width

MEDIA

Figure 3-1 Media Orientation

AG45200 Rev. 2 53
Installing and Removing a Pin Bar
The pin bar is located inside the autoloader unit, in a channel on the
left side of the input tray. (See Figure 3 - 2, View A.)
PICKUP ASSY RAIL
SUPPORT

CHANNEL

PIN BAR

INPUT SHELF

Figure 3 - 2 Pin Bar Location

Figure 3 - 2, View B shows the main parts of the pin bar. The
alignment pin keeps 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.

54 AG45200 Rev. 2
 Installing a Pin Bar
With the platesetter and the control workstation running...

Step 1. In CtServer, click the “Pause Output” button, and then

click the “Change Media” button. Select a media type
that requires a pin bar that is different from the one
loaded in the platesetter.
Step 2. When instructed to do so, remove the autoloader top
cover and right side cover.
Step 3. If necessary, remove the existing pin bar as explained in
“Removing a Pin Bar” on page 56.
Step 4. Hold the new pin bar with the latch end in your left hand
and the alignment pin end in your right hand.
Step 5. Look for the small hook at the front of the channel (see
the next figure).

FRONT OF
CHANNEL

HOOK

Figure 3 - 3 Alignment Pin Hook

Step 6. Position the pin bar over the channel with the align-
ment-pin end at the front of the channel and the latch at
the back of the channel.

Step 7. Hold the pin bar at a 45o angle and snap the pin bar
alignment pin into the hook (see Figure 3 - 4).

AG45200 Rev. 2 55
 Step 8. Press down on the alignment pin so that it stays in the
hook, and then lower the other end the pin bar into the
channel until the latch snaps and locks the bar in place.
Step 9. Press down on the center of the pin bar to make sure it is
properly seated.
HOOK

ALIGNMENT PIN

PIN BAR

CHANNEL
Figure 3 - 4 Setting the Alignment Pin in the Hook

Step 10. Replace the autoloader covers.

Removing a Pin Bar

With the platesetter and control workstation running and CtServer
output paused...

Step 1. Select Change Media. Select a media type that requires a

pin bar that is different from the one loaded in the
platesetter.
Step 2. When prompted to do so, remove the autoloader top
cover and right side cover.
Step 3. Locate the pin bar (see Figure 3 - 2).

Step 4. Lift the pin bar up by the latch until the bar is at a 45o
angle.
Step 5. At the front of the pin bar, disengage the alignment pin
from the hook in the channel, and then remove the pin
bar.

56 AG45200 Rev. 2
Mounting a 60-Plate Cassette on the Cart
On 60-plate cassette systems, the cassette and the cassette cart are
separate items. (In 250-plate cassette systems, the cassette includes
its own integrated cart.)

Mounting the Cassette

Step 1. Read and observe the safety precautions outlined on
page 52.
Step 2. Set the cassette on top of the cart (Figure 3 - 5).
Step 3. Ensure that the front of the cassette is flush against the
cart shelf. (See detailed view in Figure 3 - 5).

LIGHT SHIELD
COVER

CASSETTE

FRONT OF
CASSETTE
SHELF
Figure 3 - 5 Plate Cassette and Cart

Step 4. Turn the knurled knobs on the cassette cart handle

clockwise. As you do, the front end of the locking levers

AG45200 Rev. 2 57
 (see Figure 3 - 6) pivot upward and engage the cassette,
locking it in place on the cart.
Step 5. Roll the cart to the platesetter.
Step 6. Load the cassette into the platesetter as explained on
page 73.
LOCKING LEVER
KNURLED KNOB

Figure 3 - 6 Cassette Locking Mechanism

Dismounting the Cassette

Once the cassette is locked in the autoloader, the cart can be
removed. To remove the cart from the cassette (with the cassette
mounted in the platesetter):

Step 1. Turn the knurled knobs on the cassette cart handle

counterclockwise to disengage the mechanism that
locks the cassette in place on the cart.
Step 2. Slowly pull the cart away from the platesetter until the it
clears the cassette, which is now being supported by the
shelf at the front of the platesetter.
Step 3. Roll the cart to another location for use there.

58 AG45200 Rev. 2
Loading a 60-plate PSS Cassette
Plates must be allowed to acclimate to room temperature before
loading. Failure to allow the plates to acclimate may cause the
permanent slip sheets to stick to the plates, resulting in plate jams.

Opening the Cassette

Step 1. In a safelight environment, position the cassette cart

next to the supply of new plates.
Step 2. Set the two cassette light shield locks all the way down,
into the UNLOCKED position, as shown below.
LIGHT SHIELD
LOCKS

UNLOCKED LOCKED
POSITION POSITION
Figure 3 - 7 Light Shield Lock Positions

AG45200 Rev. 2 59
 Step 3. Slide the light shield to the back of the cassette cover as
shown in Figure 3 - 8.
Step 4. Make sure the edge of the light shield is completely out
of the channel shown in the exploded view in Figure 3 -
8.

LIGHT SHIELD

CHANNEL

EDGE OF
LIGHT SHIELD

Figure 3 - 8 Light Shield, Fully Open

Step 5. Open the cassette cover as shown below.

CASSETTE COVER

Figure 3 - 9 Cassette Cover, Open

60 AG45200 Rev. 2
 Step 6. Move the permanent slip sheets out of the cassette and
drape them over the cassette cover as shown below.

SLIP SHEETS

Figure 3 - 10 Draping the Slip Sheets over the Cover

Adjusting the Alignment Pins

Step 1. Set one plate into cassette emulsion side up (see Figure
3 - 11).
Step 2. Move the plate flush against the left side wall, and then
forward until the leading edge of the plate contacts the
velcro pads. (See Figure 3 - 11.)
VELCRO
LEFT PADS
SIDE WALL

TRACK B

TRACK A

ALIGNMENT
PIN

Figure 3 - 11 Alignment Pin and Tracks

AG45200 Rev. 2 61
 Step 3. Determine if any alignment pins need to be moved to a
different track to make contact with the plate. For exam-
ple, the alignment pin shown in Figure 3 - 11 needs to be
moved from track A to track B in order to make contact
with the plate.
Step 4. To move an alignment pin from one track to another, use
the 5/32” Allen wrench provided with the cassette and
proceed as follows:
•Loosen the hex screw that secures the alignment
pin shown in Figure 3 - 12.
•Slide the pin forward to the end of the track.
•Lift the pin assembly straight up and out of the
track.
•Remove the plate from the cassette.
WRENCH

ALIGNMENT
PIN
SCREW

Figure 3 - 12 Alignment Pin Assembly

•Set the alignment pin into the front of the new slot,
as shown in the next figure.

62 AG45200 Rev. 2
 ALIGNMENT TRACK
PIN

FRONT
OF TRACK
Note: Make sure to keep
the washer above the
track, as shown here.
WASHER
Figure 3 - 13 Alignment Pin at Front of Track

•Slide the alignment pin to the back end of the track but do
not tighten the locking screw.

Step 5. Set the plate back into the cassette as explained in step
2.
Step 6. Set the side alignment pins against the side of the plate,
and the back alignment pin against the trailing edge of
the plate.
Step 7. Adjust each adjustment pin as required to establish a 1/
16” (1.6 mm) gap between the pin and the plate, and
then tighten the pin locking screw. (When the edge of
the pin mount and the edge of the plate line up as shown
below in View B, the gap is correct.)

1/16” (1.6 mm) GAP

Edge of
Plate

Edge of
Pin Mount

VIEW A VIEW B

Figure 3 - 14 Gap between Pin and Plate

AG45200 Rev. 2 63
 Loading Plates into the Cassette

Step 1. Carefully lift the top-most slip sheet off the stack and set
it on the bottom of the cassette, as shown in Figure 3 -
15, View A.
Step 2. Flatten the slip sheet as shown in Figure 3 - 15, View B.

slip sheet

VIEW A VIEW B

PLATE

VIEW C VIEW D
Figure 3 - 15 Loading Plates into the Cassette
Step 3. Carefully set one plate over the slip sheet as shown in
Figure 3 - 15, View C. Align the plate flush against the
side and front of the cassette, and make sure there is a 1/
16” gap between the edge of the plate and the alignment
pins.

64 AG45200 Rev. 2
 Step 4. As you did before,
carefully lift the LOADING NOTES
next slip sheet off
the stack and set it • Allow plates to acclimate to room tem-
on top the plate perature before loading them into the
you just set into the cassette. If you don’t, the permanent
cassette as shown slip sheets may stick to the plates.
in Figure 3 - 15, • Always set one slip sheet down in the
View D. cassette before loading in the first
plate.
Step 5. Repeat steps 3 and • If you do not fill the cassette to capacity,
4 until you fill the place the unused slip sheets over the
cassette. Make sure top plate in the cassette.
to set every plate
flush against the • Be sure to maintain the 1/16” gap
between the plate and the alignment
side and front of pins on every plate you load into the
the cassette. This cassette. If the gap is not uniformly
will insure an even, maintained throughout the stack of
uniform 1/16” gap plates, problems resulting from plate
“wedging” may occur.
between the plates
and the alignment • Sometimes paper slip sheets stick to
pins along entire the bottom of plates while they are
stack of plates. being removed from the packaging.
Make sure to check for and remove
such paper slip sheets before loading
Step 6. Close the cassette plates into the cassette.
cover.
Step 7. Guide the light shield into the channel shown in Figure
3 - 8, and then slide the shield into the fully closed posi-
tion.
Step 8. Set the shield locks into locked position as shown in
Figure 3 - 7.
Step 9. If necessary, mount the cassette to the cart. (See
“Mounting a 60-Plate Cassette on the Cart” on page 57.)
Step 10. Roll the cart to the platesetter and load the cassette into
the platesetter. (See “Loading the Cassette into the
Autoloader” on page 73.)

AG45200 Rev. 2 65
Loading an SSR Cassette (60- or 250-plate)
This section explains how to load cassettes used in systems that
have an automatic slip sheet removal (SSR) system.
Some SSR systems are designed to work with a 60-plate cassette
while others are designed to work with a 250-plate cassette. A 250-
plate cassette cannot be used in 60-plate system, and a 60-plate
cassette cannot be used in a 250-plate system.
The same loading / handling procedures apply to the 60-plate and
the 250-plate cassette. Plates are loaded in a stack at a time, straight
out of the shipping carton, without removing the paper interleaf slip
sheets. The cardboard sheets that protect the top and bottom plates
in the stack should NOT be loaded into the cassette.

Opening the Cassette

Step 1. In a safelight environment, position the cassette cart
next to the supply of new plates.
Step 2. Set the two cassette light shield locks all the way down,
into the UNLOCKED position, as shown below.
LIGHT SHIELD
LOCKS

UNLOCKED LOCKED
POSITION POSITION

Figure 3 - 16 Light Shield Lock Positions

66 AG45200 Rev. 2
 Step 3. Slide the light shield to the back of the cassette cover as
shown in Figure 3 - 17.
Step 4. Make sure the edge of the light shield is completely out
of the channel shown in the exploded view in Figure 3 -
17.

LIGHT SHIELD

CHANNEL

EDGE OF
LIGHT SHIELD

Figure 3 - 17 Light Shield, Fully Open

Step 5. Open the cassette cover as shown below.

CASSETTE COVER

Figure 3 - 18 Cassette Cover, Open

AG45200 Rev. 2 67
 Adjusting the Alignment Pins
Step 1. Set one plate into cassette emulsion side up. (See
Figure 3 - 19.)
Step 2. Move the plate flush against the left side wall, and then
forward until the leading edge of the plate contacts the
velcro pads. (See Figure 3 - 20.)
LEFT VELCRO
SIDE WALL MAX PADS

TRACK B

TRACK A

ALIGNMENT
PIN

Figure 3 - 19 Alignment Pin and Tracks

Step 3. Determine if any alignment pins need to be moved to a

different track to make contact with the plate. For exam-
ple, the alignment pin shown in Figure 3 - 19 needs to be
moved from track A to track B in order to make contact
with the plate.
Step 4. To move an alignment pin from one track to another, use
the 5/32” Allen wrench provided with the cassette and
proceed as follows:
a)Loosen the hex screw that secures the alignment pin.
b)Slide the pin forward to the end of the track

68 AG45200 Rev. 2
 c)Lift the pin assembly straight up and out of the track.
Note: This figure shows a 250-plate cassette.
In 60-plate cassettes, the screw is on top of the WRENCH
pan, not below it as shown here.
.

ALIGNMENT
PIN SCREW
(IS BELOW THE PAN)

Figure 3 - 20 Alignment Pin Assembly

d)Remove the plate from the cassette.
e)Set the alignment pin into the front of the new track, as
shown in Figure 3 - 21.
f) Slide the pin all the way to the back of the track.

60-Plate Cassette
Alignment Pin ALIGNMENT TRACK
PIN

FRONT
OF TRACK
Note: Make sure to keep
the washer above the
track, as shown here.
WASHER

250-Plate Cassette TRACK

Alignment Pin ALIGNMENT Note: Make sure to keep

PIN
the washer below the
track, as shown here.
FRONT
OF TRACK
BASE OF
CASSETTE
WASHER &
LOCKING PLATE

Figure 3 - 21 Alignment Pin at Front of Track

AG45200 Rev. 2 69
 Step 5. Slide each alignment pin to the back end of its track. Do
NOT tighten the alignment pin mounting screw.

Loading Plates into the Cassette

Step 1. Ask a co-
worker to LOADING NOTES
help you
unpack and • There should NOT be a slip sheet between
load plates the bottom plate and the base of the cassette.
into the • There should be one slip sheet covering
cassette. every plate in the stack, including the top
plate.
Step 2. Read the
LOADING • Cardboard separators sometimes used to
NOTES at the package plates MUST BE REMOVED.
right. • There must be a 1/16” gap between the stack
of plates and the alignment pins. If the gap is
Step 3. Unpack a not uniformly maintained throughout the stack
stack of new of plates, problems resulting from plate
“wedging” may occur.
plates and set
the stack into • Do not overfill the cassette.
the cassette as
shown in Fig- • For secondarily cut plates, put the rough edge
in the front.
ure 3-23.
Step 4. Push the stack of plates flush against the left side wall
and against the velcro pads at the front of the cassette, as
shown below.
LEFT STACK OF VELCRO
SIDE WALL PLATES PADS
MAX

CASSETTE
BASE

ALIGNMENT
PIN

Figure 3 - 22

70 AG45200 Rev. 2
 Step 5. Fan the back, corners, and sides of the stack of plates a
few times as shown below to decompresses the stack.
Note: This is an important step. If the stack is not fanned, plates
and slip sheets tend to stick together when the pickup
mechanism tries to separate them.

Figure 3 - 23 Fanning the Stack of Plates

Step 6. Square off the entire stack of plates, making sure all the
plates line up and are flush against the cassette side wall
and the front wall.

AG45200 Rev. 2 71
 Step 7. Slide all three alignment pins flush against the stack of
plates (see Figure 3 - 24).
Note: There may be times when only two pins can be
STACK OF used (e.g., single truck plates). When this is the case,
PLATES set the third pin in an out-of-the-way location.

ALIGNMENT
PIN

ALIGNMENT
PINS
Figure 3 - 24 Setting the Alignment Pins

Step 8. Pull back each adjustment pin slightly to establish a 1/

16” (1.6 mm) gap between the pin and the stack of plates
(View A below), and then tighten the pin locking screw.
(If the edge circular base of the alignment pin and the
edge of the plates line up as shown in View B, the gap is
correct.)
Note: This figure shows a 250-plate cassette. In a 60-plate
cassette, the alignment pin mounting hardware is on top
of the pan, rather than below it. The 1/16” gap shown
here is required in both 250- and 60-plate cassettes.
Edge of
1/16” (1.6 MM) GAP Plates

Circular Base
of
Alignment Pin
VIEW A VIEW B
Figure 3 - 25 Gap between Pin and Plates

72 AG45200 Rev. 2
 Step 9. Close the cassette cover.
Step 10. Guide the light shield into the channel shown in Figure
3 - 17, and then slide the shield into the fully closed
position.
Step 11. Set the shield locks into locked position as shown in
Figure 3 - 16.
Step 12. Roll the cart to the platesetter and load the cassette into
the platesetter. (See “Loading the Cassette into the
Autoloader” on page 73.)

Loading the Cassette into the Autoloader

Two loading procedures follow. Follow the one that pertains to
your cassette.

Loading a 60-Plate Cassette

Step 1. Ensure the cassette light shield is closed and locked.

Step 2. Roll the cassette cart in front of the platesetter.
Step 3. Carefully guide the front of the cassette through the
input slot (Figure 3 - 27) and into the autoloader.

CONTROL
PANEL

INPUT SLOT

SHELF
CASSETTE

Figure 3 - 26 Input Area, 60-Plate Cassette

AG45200 Rev. 2 73
 Step 4. Push the cart/cassette forward until you feel a lock
engage the cassette.
Step 5. Pull the cart/cassette back slightly to make sure the lock
is engaged, and then push it forward again until the cas-
sette is all the way back in the autoloader.
NOTE: If the cassette is not all the way in, the system will
report an interlock error. The alarm will sound and a
control panel light will blink. If this happens, push the
cassette all the way into the autoloader, and then
press the control panel OK button.

Loading a 250-Plate Cassette

Step 1. Ensure the cassette light Note: A fully leaded cassette

shield is closed and locked. is easier to load than a
partially loaded one.
Step 2. Roll the cassette assembly in
front of the platesetter.
Step 3. Align the arrow on the top of the cassette with the three
arrows on the top of the lift mechanism.
Step 4. Push the cassette forward until the cassette guide rails
make contact with the lift mechanism input rollers (see
figure below).
CASSETTE

LIFT MECHANISM

GUIDE RAIL
INPUT ROLLER

Figure 3 - 27 Input Area, 250-Plate Cassette

74 AG45200 Rev. 2
 Step 5. Push the cassette cart forward until you feel the cassette
drop into locked position.
Step 6. Pull the cart/cassette back slightly to make sure the lock
is engaged, and then push it forward again until the cas-
sette is all the way back in the autoloader.
NOTE: If the cassette is not all the way in, the system will
report an interlock error. The alarm will sound and a
control panel light will blink. If this happens, push
the cassette all the way into the autoloader, and then
press the control panel “OK” button.

Refilling the Cassette when Plates Run Out

When the cassette plate supply is exhausted, the control panel
displays a “NO PLATES” message, the ATTENTION light blinks,
and the “Select Plate Type” window automatically opens in
CtServer.

• To refill the cassette with the same type of plate, see “Refilling
the Cassette with the Same Type of Plate” on page 75.
• To refill the cassette with a different type plate refer to “Refill-
ing the Cassette with a Different Type of Plate” on page 77.

Refilling the Cassette with the Same Type of Plate

Step 1. In CtServer, in the “SELECT PLATE TYPE” dialog,
click OK.
Step 2. The “Waiting for Operator to add more plates...” mes-
sage appears on the screen. This is a prompt for you to
remove the cassette from the machine and reload plates.
Note: The recorder will wait until the last plate is in the processor
before prompting you to close the cover.

Step 3. Go to the platesetter. The control panel displays a

“CLOSE CASSETTE COVER” message. This is a
prompt to close the light shield.
Step 4. Push the cassette light shield forward until you hear the
locking mechanism disengage.

AG45200 Rev. 2 75
 Step 5. Set the locks on the light shield up, into locked position.
Note: If your system performs automatic slip sheet removal, a
prompt to empty the slip sheet bin may appear on the control
display. If so, empty the bin.

Step 6. The control panel displays the following message:

NO PLATES RELOAD
[pin bar name]
[plate type name]
CANCEL for NEW PLATE

Step 7. If the plates in the cassette and the pin bar in the machine
are correctly identified on the display, go to the next
step.
Otherwise, press the Cancel key, go back to CtServer,
and select plate type and/or pin bar settings that match
the plate type and pin bar to be used.
Step 8. Pull the cassette cart back so as to remove cassette from
the autoloader.
Note: If the lock resets before you get the cassette all the way out,
press the OK button. The lock will disengage for another 5
seconds.

Step 9. Load plates into the cassette. See “Loading Plates into
the Cassette” on page 64.
Step 10. Insert the cassette into the autoloader. See “Loading the
Cassette into the Autoloader” on page 73.
Step 11. An OPEN CASSETTE COVER message appears on
the control panel to prompt you to retract the light shield.
Step 12. Unlock the cassette light shield locks and pull the
shield all the way to the front (toward you).
Step 13. A PRESS OK TO CONTINUE message appears on the
control panel.
Step 14. Press OK to confirm you have completed all the steps.
The Attention light finally stops blinking.
Step 15. Go to the control workstation.

76 AG45200 Rev. 2
 Step 16. In CtServer, click the RESUME OUTPUT button. The
system resumes imaging the jobs.

Refilling the Cassette with a Different Type of Plate

Step 1. In the CtServer “SELECT PLATE TYPE” window,
select the appropriate plate type. The associated pin bar
displays automatically.
Step 2. Ensure “Cassette” is selected as the Media Source.
Step 3. Click OK.
Step 4. A “Waiting for Operator to ready a cassette with [plate
name] plates...” message appears on the screen. This is a
prompt to remove the cassette and load plates.
Step 5. Go to the platesetter. The control panel displays a
“CLOSE CASSETTE COVER” message. This is a
prompt to close the light shield.
Note: The recorder will wait until the last plate is in the processor
before prompting you to close the cover.

Step 6. Push the cassette light shield forward until you hear the
locking mechanism disengage.
Step 7. If a pin bar change is required, the control panel dis-
plays this new message:
CHANGE BAR
[pin bar name]
.....................
NO PLATES

Step 8. Remove the autoloader top cover.

Step 9. Determine if the pin bar in the machine is the one iden-
tified on the control panel display. If not, remove the pin
bar and replace it with the one specified on the display.
Step 10. Replace the autoloader cover(s). A new message
appears on the control panel display:
CHANGE CASSETTE
[pin bar name]
[plate type name]
NO PLATES

AG45200 Rev. 2 77
 Step 11. Pull the cassette out of the autoloader. A few seconds later, you
will hear the cassette locking mechanism engage.
Note: If the lock resets before you get the cassette all the way out,
press the OK button. The lock will disengage for another 5
seconds.

Step 12. Load plates into the cassette. See “Loading Plates into
the Cassette” on page 70.
Step 13. Insert the cassette into the autoloader. See “Loading the
Cassette into the Autoloader” on page 73.
Step 14. An OPEN CASSETTE COVER message appears on
the control panel. This is a prompt to retract the light
shield.
Step 15. Unlock the cassette light shield locks and pull the
shield all the way to the front (toward you).
Step 16. A PRESS OK TO CONTINUE message appears on the
control panel.
Step 17. Press OK to confirm you have completed all the steps.
The Attention light finally stops blinking.
Step 18. Go to the control workstation.
Step 19. In CtServer, click the RESUME OUTPUT button. The
system resumes imaging jobs that require the loaded
plate.

Topping Off the Cassette Supply

When the CtServer MEDIA REMAINING bar indicates the
cassette plate supply is low, you may want to replenish the supply
before it becomes exhausted. Here’s how to do that.

Step 1. In CtServer, click the PAUSE OUTPUT button and wait

for imaging to complete.
Step 2. Click the CHANGE MEDIA button.
Step 3. In the “SELECT PLATE TYPE” window, select the
current plate type. When you do, the “associated pin
bar” automatically displays.

78 AG45200 Rev. 2
 Step 4. In the same window, select “cassette” for plate source,
and then click OK.
Step 5. A “Waiting for Operator to add more plates...” message
appears on the screen. This is a prompt for you to
remove the cassette and reload plates.
Step 6. Go to the platesetter. When the control panel displays a
“Close Cassette Cover” message, close the light shield.
Note: This message does not display until the last plate imaged is
in the processor.

Step 7. Push the cassette light shield forward until you hear the
locking mechanism disengage.
Step 8. Set the light shield locks up, into locked position.
Step 9. Note the control panel display, which now reads:
ADD MORE PLATES
[pin bar name]
[plate type name]
CANCEL for NEW PLATE

Step 10. If the plates in the cassette and the pin bar in the
machine are correctly identified on the display, go to the
next step. Otherwise, press Cancel, go back to CtServer,
and select plate type and/or pin bar settings that match
the plate type and pin bar actually being used.
Step 11. Pull the cassette cart back so as to remove cassette
from the autoloader.
Note: If the lock resets before you get the cassette all the way out,
press the OK button. The lock will disengage for another 5
seconds.

Step 12. Load plates into the cassette. See “Loading Plates into
the Cassette” on page 64.
Step 13. Insert the cassette into the autoloader. See “Loading
the Cassette into the Autoloader” on page 73.
Step 14. An “Open Cassette Cover” message appears on the
control panel. This is a prompt to retract the light shield.

AG45200 Rev. 2 79
 Step 15. Unlock the cassette light shield locks and pull the light
shield all the way back (toward you).
Step 16. A “Press OK to Continue” message appears on the con-
trol panel.
Step 17. Press the OK button to confirm you performed the pre-
vious steps. The”Attention” light finally stops blinking.
Step 18. Go to the control workstation.
Step 19. In CtServer, click the RESUME OUTPUT button. The
system resumes imaging jobs.

Defining and Loading a New Plate Type

The following are general directions for defining a new plate type.
For more detailed instructions, refer to the CtServer for MAKO CTP
Systems Operator Guide AG45199 on the CtServer Software CD.

Step 1. In CtServer, go the Media and Exposure Settings panel

and click the plate and bars tab.
Step 2. Click “Add...” in the Plate Definitions section.
Step 3. Type in a new plate name. Use a naming convention like
the plate length, width, and thickness, or the name of the
press the plate will be used on.
Step 4. Enter the plate length, width, and thickness dimensions.
Step 5. Select an associated pin bar.
Step 6. Click OK.
You have defined the new plate type. You may now load
one or more of the new plates into the cassette. To do so,
continue with the next step.
Step 7. Click PAUSE OUTPUT.
Step 8. Click CHANGE MEDIA
Step 9. Go to the SELECT PLATE TYPE screen and select the
new plate type. (After you do, the associated pin bar
automatically displays.)

80 AG45200 Rev. 2
 Step 10. Select the required media source (cassette), and then
click OK.
Step 11. A “waiting for operator to ready a cassette with [plate
name] plates” message appears. This is a prompt for
you to load the new plate(s) into the cassette.
Step 12. Go to the platesetter control panel.
Step 13. The “Close Cassette Cover” message appears on the
display when the last plate is in the processor.
Step 14. Close and lock the cassette light shield.
Note: If your system performs automatic slip sheet removal, a
prompt to empty the slip sheet bin may appear on the con-
trol display. If so, empty the bin.

Step 15. A new message appears that identifies the pin bar that
should be used with the new plate type. Verify that the
displayed pin bar is installed in the machine. If it is not,
remove the exiting pin bar and replace it with the one
specified on the display. See “Installing and Removing
a Pin Bar” on page 54.
Step 16. The “Change Cassette Message” appears and the cas-
sette unlocks.
Step 17. Pull the cassette out of the platesetter. A few seconds
later, you will hear the cassette locking mechanism
reset.
Note: If the lock resets before you get the cassette all the way out,
press the OK button. The lock will disengage for another 5
seconds.

Step 18. Roll the cart and cassette to the safelight plate loading
area.
Step 19. Load the cassette with the required plates. See “Load-
ing Plates into the Cassette” on page 64.
Note: Remember to set the exposure before to sending a job that
uses the new plate type.

AG45200 Rev. 2 81
Manually Loading a Plate
Note: Always handle plates carefully. Be gentle when positioning
a plate against the registration pins. Thin plates are espe-
cially susceptible to dings and dents.

Step 1. Ensure the platesetter is in safelight operating

environment.
Step 2. In CtServer, click the PAUSE OUTPUT button.
Step 3. Click the CtServer CHANGE MEDIA button.
Step 4. Select the plate you want to run.
Step 5. In the CHANGE MEDIA TYPE window, for MEDIA
SOURCE, select “manual.”
Step 6. Click the RESUME OUTPUT button. Jobs requiring the
new plate type will become eligible.
Step 7. The alert light on top of the platesetter flashes and the
control panel displays a series messages, the last of
which is:
LOAD A PLATE
[pin bar name]
[plate name]

Step 8. Remove the autoloader top cover and side cover(s).

Step 9. Verify the correct pin bar is installed.
Step 10. Carefully place the plate on the platesetter input shelf.
Step 11. If the plate is less than 35 inches (89 cm) long, set it
against the registration pins as shown in Figure 3 - 28,
Step A, and then slide the plate forward until the leading
edge lines up with the front edge of the input shelf, as
shown in Figure 3 - 28, Step B

82 AG45200 Rev. 2
 FRONT EDGE OF
INPUT SHELF FRONT EDGE OF
INPUT SHELF

REGISTRATION
PIN
LEADING
EDGE OF
LEADING PLATE
EDGE OF
PLATE

SIDE EDGE
OF PLATE

REGISTRATION PLATE
PIN

PIN BAR

VIEW A VIEW B

Figure 3 - 28 Loading a Short Plate

Step 12. If the plate is 35 inches (89 cm) or longer:

a) Set the plate against the registration pins as
shown above in Figure 3 - 28, Step A.
b) Slide the plate forward until the trailing edge of
the plate clears the cassette and is resting on the
pan cover and contacting the front of the plate
cassette as shown in Figure 3 - 29. (On slip

AG45200 Rev. 2 83
 sheet removal systems, the trailing edge should
contact the light shield cover.)
PAN COVER

Figure 3 - 29 Loading a Long Plate

Step 13. Replace the autoloader covers.

Step 14. Press the control panel “OK” button. The plate
advances into the imaging unit and is imaged.

Emptying the Slip Sheet Disposal Bin

Bin Counter
The slip sheets that accumulate in the disposal bin must be cleared
out from time to time.To help you know when to empty the bin, the
system

• Keeps track of the total number of slip sheets that are in the bin
• Displays the bin count on the control panel display
• Displays prompts to empty the bin when the count exceeds pre-
set levels you define.

84 AG45200 Rev. 2
 The User Preferences menu includes options for specifying
separate bin capacities for “big” and “small” slip sheets, and an
option for defining the cut-off size to switch between the capacities.
For more about these parameters, see page 28.

Emptying the Bin

To empty the bin:

Step 1. Slide open the access door shown below

If a loaded cassette is in the platesetter, make sure to
close and lock the cassette light shield before
opening the access door.
Note: Opening and closing the access door while the power is on
resets the bin counter to zero.

ACCESS
BIN DOOR

Figure 3 - 30 Bin and Access Door

Step 2. If your system has a slip sheet compactor, carefully

clear away any discarded slip sheets that may be sur-
rounding the compactor before you remove the rest of
the slip sheets.
Step 3. Grasp the top and bottom of the slip sheet tangle at the
places marked “X” in View A, below. Ensure the top
of the tangle is below the compactor arms.
Step 4. Using a continuous clockwise motion, begin twisting
the tangle into a tight roll as shown in View B, below.
Step 5. Continue twisting until nearly all the slip sheets are
rolled up and facing the door opening as shown in View
C, below.

AG45200 Rev. 2 85
 Step 6. Pull the roll of slip sheets straight out through the door
opening.
Outline of Bin
Door Opening
Slip Sheet Tangle

VIEW A VIEW B VIEW C

Figure 3 - 31 Removing Slip Sheets from the Bin

The Slip Sheet Compactor

Some models include a mechanical slip sheet compactor. The
compactor periodically compresses the slip sheet pile against the
bottom bin to maximize its storage capacity.
The storage capacity of the bin varies depending on the slip sheet
size and environmental factors like temperature and humidity. In a
system equipped with a compactor, the following are nominal
capacities for two slip sheet sizes.
Slip sheet Size Bin Capacity Note: In models without a
compactor, bin capacity is less
22'' W x 22'' L 460 slip sheets than shown at the left.
22'' W x 38'' L 380 slip sheets

A magnetic sensor is used to monitor the compactor’s return to

“home” (up) position at the end of every compression cycle. When
the sensor fails to detect such a return to the home position, the
platesetter halts normal operation and displays a “Compactor Timed
Out” error message.
If you see such a message, call ECRM customer service for help
correcting the problem.

86 AG45200 Rev. 2
Emptying the Chad Container
If the platesetter is
equipped with a plate
punch you will have
to empty the chad
container from time
to time.
The container is
located on the left CHAD
side of the machine, CONTAINER
as shown at the right. Figure 3 - 32 Chad Container
Small holes along the
container provide a means for checking the chad level inside
the container. When the container is about half full, remove
it, discard the chad, and then replace the container.

Removing/Emptying the Container

Step 1. Lift the container straight up to disengage it from the

chute.
Step 2. Empty the container.

AG45200 Rev. 2 87
 Replacing the Container

Step 1. Set the

container OVERHANG
flush against
the base LIP
directly
above the
chute.
Step 2. Push the
container
down to
mount it on
the chute.
Make sure
the overhang Figure 3 - 33 Container Mounting
inside the
container fits
over the lip at the top of the chute.

88 AG45200 Rev. 2
 Maintenance and
Troubleshooting
4
Introduction
This chapter describes:

• “Cleaning the System” on page 89

• “Lubricating the System” on page 98
• “Clearing Misfeeds” on page 102
• “Aligning the Platesetter and the Processor” on page 103
• “Adjusting the Height of the Cassette” on page 107

Cleaning the System

This section explains how to keep the system clean and in good
working order.
Items requiring regular cleaning are presented in a table on the next
page. The table also includes a 12-month cleaning schedule. We
recommend you maintain the cleaning schedule. We also
recommend you make use of the system’s capability to display
maintenance reminders on the control panel. For more about this,
see page 26,
Remember to shut the power off to the machine before doing any
internal maintenance procedures. Use only the recommended
cleaners. Make sure that cleaning supplies are lint and dirt free.

AG45200 Rev. 2 89
90
Table 1: Cleaning Schedule
Cleaning Periods Item Recommended For Details,
Requiring Cleaner Refer to...
Cleaning

Month 1
Month 2
Month 3
Month 4
Month 5
Month 6
Month 7
Month 8
Month 9
Month 10
Month 11
Month 12
After 48 hours of non use
Every 500 plates
As Required
24”-Wide Transport General Purpose “Media Transport Belt (24”-wide Belt)”
3 3 3 3
Belt Cleaner & Alcohol on page 97
3 3 3 3 Fan Filters Mild Soapy Water “Fan Filters” on page 92
Drive Rollers General Purpose “Cleaning the Drive Roller” on page 95
3 3 3 3
Cleaner
Pinch Rollers PH0046 “Cleaning the Pinch Roller” on
3 3 3 3
Roller Cleaner page 96
3 3 3 3 Cassette Exterior Mild Detergent “Plate Cassette” on page 96
3 3 3 3 Cassette Interior Vacuum Cleaner “Plate Cassette” on page 96
3 3 Pin Bars Mild Detergent “Pin Bar” on page 88
Transport Isopropyl Alcohol “Media Transport Output Sensor” on
3 3
Output Sensor page 97
3 3 Exterior Mild Detergent “Platesetter Exterior” on page 91
Slip Sheet Isopropyl Alcohol Rub in liberal amounts of alcohol while
3
Disposal Unit Rollers turning the rollers by hand.
Vacuum Cups A Lint-free Cloth “Vacuum Cups” on page 91
3

3 Ionizer Bar Clean, Soft Toothbrush “Ionizer Bar” on page 98

AG45200 Rev. 2
 Pin Bar
Clean the pin bar with any mild detergent in clean water using a
soft, cotton cloth. Don’t use abrasive cleansers or chemical
cleansers.

Platesetter Exterior
Clean the outside of the platesetter with any mild detergent in clean
water using a soft, cotton cloth. Don’t use abrasive cleansers or
chemical cleansers.

Vacuum Cups
The vacuum cups should be cleaned occasionally to remove
contaminant build-up. The recommended frequency is once every
500 plates.
To clean the vacuum cups, obtain a clean lint-free cloth and
proceed as follows:

Step 1. At the control panel, select the User Maintenance

Menu. See “User Maintenance Menu” on page 31.
Step 2. Scroll to the “Enable User Access” option.
Step 3. If a cassette is installed, a “CLOSE CASSETTE” mes-
sage appears on the display. This is a prompt to close
and lock the cassette light shield. Do both.
Step 4. Press the OK key. A “PARKING MOTORS” message
momentarily appears on the display, followed by a
“USER ACCESS MODE” message. The cassette lock
opens.
Step 5. Press OK.
Step 6. Remove the autoloader covers and set them aside.
Step 7. Using the lint-free cloth, wipe the bottom of the vacuum
cups to remove the contaminant build-up.
Step 8. Replace the autoloader covers.

AG45200 Rev. 2 91
 Step 9. Press MENU.
Note: Dirty cups can cause plate pickup failures and/or plate regis-
tration problems.

Fan Filters
Four filtered fans run at all times to maintain an air flow inside the
platesetter and the transport assembly. The filters can become
clogged with dust and debris if they are 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.

Platesetter Fan Filters

Two filtered fans provide positive air
pressure to the platesetter. To remove
and replace the filters for the fans:

Step 1. Turn the power switch off.

Step 2. On either side of the
machine, locate the fan fil-
ter assembly. It is posi-
tioned in a slot at the FILTER ASSEMBLY
bottom of the rear main
cover.

92 AG45200 Rev. 2
 Step 3. Place your finger in the finger hole and gently pull the
filter out of the slot.

REAR
MAIN COVER

FAN
FILTER

SLOT
FINGER
HOLE

Figure 4-1 Platesetter Fan Filter Removal / Replacement

Step 4. Wash the filter in mild, soapy water. Rinse in clean

water and dry.
Step 5. Place the filter back into the slot.
Step 6. Repeat the same procedure for the other filter, which is
located on the opposite side of the platesetter.

Transport Fan Filters

Two filtered fans provide positive air pressure to the media transport
unit.

AG45200 Rev. 2 93
 The filters for the fans are located underneath the transport.
POWER
SWITCH
FAN
FILTERS

Figure 4 - 2 Media Transport Fan Filters

To remove and replace either filter:

Step 1. Turn the power switch off.

Step 2. Locate the fan filter. It is positioned over a hole in the
pan, where it is snugly fitted between the fan guard and
the pan.
Step 3. Gently pinch the filter to get hold of it, and then care-
fully pull it out from between the fan guard and the pan.
FAN
FILTER
GUARD

HOLE
IN PAN

Figure 4 - 3 Removing the Fan Filter

Step 4. Wash the filter in mild, soapy water. Rinse in clean

water and dry.
Step 5. Place the filter back in position between the fan and the
opening in the pan.
Step 6. Repeat the same procedure for the other filter, which is
located on the opposite side of the platesetter.

94 AG45200 Rev. 2
 Front (Input) Rollers
Cleaning the rollers will cut down on the contaminants running
through the media system. Dirty rollers can cause contamination of
the media.

“O” RINGS

PINCH
ROLLER

DRIVE
ROLLER

Figure 4 - 4 Front (Input) Rollers

Cleaning the Drive Roller

Step 1. Use the User Maintenance Menu to gain access to the

inside of the autoloader, per the ENABLE USER
ACCESS option. See “User Maintenance Menu” on
page 31.
Step 2. Remove the autoloader top cover and side covers.
Step 3. Use the User Maintenance Menu to run the media roll-
ers. See “User Maintenance Menu” on page 31.
Step 4. Sparingly apply a general-purpose cleaner to a clean,
lint-free wipe.
Step 5. As the roller turns, gently wipe both the front and back
roller with the cloth, being careful to not ‘catch’ the
cloth in the roller. Do not touch the roller with bare
hands. The oils and dirt will contaminate the roller.

AG45200 Rev. 2 95
 Step 6. After cleaning the roller with a general purpose cleaner,
sparingly apply isopropyl alcohol to a clean, lint-free
wipe and then wipe the roller with the cloth.

Cleaning the Pinch Roller

Step 7. Wipe gum-contaminated pinch roller o-rings with a

water-dampened low-lint cloth.
Step 8. If water fails to remove the gum, use ECRM PH0046
roller cleaner. (Do NOT use alcohol or a general pur-
pose cleaner to clean the rollers.)
Step 9. Replace the covers.
Step 10. Exit the User Maintenance Menu.

Output Rollers
The output rollers are not accessible to an operator. The next time
the system is serviced, ask your service provider to clean the rear
roller.

Plate Cassette
Exterior - Clean the outside of the cassette with any mild detergent
in clean water using a soft, cotton cloth. Don’t use abrasive
cleansers or chemical cleansers.
Interior - Occasional vacuum cleaning of the interior of the plate
cassette is recommended to eliminate contaminants that might
otherwise be dispersed onto the surface of plates as they are being
loaded into the cassette.

Step 1. Obtain a vacuum cleaner with a soft-brush hose

attachment.
Step 2. Place the cassette on top of the cassette cart.
Step 3. Turn the knurled knobs on the cart handle to secure the
cassette on the cart.
Step 4. Open the cassette cover.

96 AG45200 Rev. 2
 Step 5. Turn on the vacuum cleaner and clean the base and side
walls of Vacuum clean the exposed surface of the cas-
sette cover.
Step 6. Close the cassette cover.

Media Transport Output Sensor

The output sensor may become dirty and require cleaning.

Step 1. The output sensor is located at the back of the transport

unit, as shown in Figure 4 - 5. If you can access the
sensor from the back of the machine, do so. Otherwise
remove the transport unit top cover.
Step 2. Using a cotton tip swab moistened with isopropyl alco-
hol, gently rub the output sensor to remove any debris
buildup.
TRANSPORT
TOP COVER

OUTPUT
SENSOR

BACK OF
TRANSPORT

Figure 4 - 5 Media Transport

Step 3. If necessary, replace the transport top cover.

Media Transport Belt (24”-wide Belt)

Step 1. At the control panel, select the User Maintenance
Menu. See “User Maintenance Menu” on page 31.

AG45200 Rev. 2 97
 Step 2. Scroll to the “Enable User Access” option.
Step 3. If a cassette is installed, a “CLOSE CASSETTE” mes-
sage appears on the display. This is a prompt to close
and lock the cassette light shield. Do both.
Step 4. Press the OK key. A “PARKING MOTORS” message
momentarily appears on the display, followed by a
“USER ACCESS MODE” message. The cassette lock
opens.
Step 5. Press OK.
Step 6. Remove the transport unit top cover.
Step 7. Use the User Maintenance Menu to run the transport.
Step 8. Using a lint-free cloth moistened with a general-purpose
cleaner, remove debris from the belt.
Step 9. Using a second lint-free cloth moistened with alcohol,
rub down the belt.
Step 10. Replace the transport unit top cover.
Step 11. Press MENU to lock the cassette and exit the menu
mode of operation.

Ionizer Bar
SSR systems include an ionizer bar. It is located in front of slip
sheet disposal rollers. Keeping the ionizing bar free of moisture and
dirt is important. The frequency of cleaning depends on the
environment in which the ionizer is installed. Dirty industrial
applications may require daily cleaning while clean-room
applications may require only monthly cleaning. Use a soft bristle
brush (e.g., a toothbrush) to remove particulates from the emitter
points and channel. Don’t use anything that will bend or dull the
emitter points. Don’t any soaps or liquid cleaners that will leave a
conductive residue.

Lubricating the System

The table on the next page lists items that need regular lubrication
and provides a schedule for lubricating the items.

98 AG45200 Rev. 2
 Table 2: 12-Month Lubrication Chart

Lubrication Required Item Requiring Suggested How to

AG45200 Rev. 2
Lubrication Lubrication Lubricate

Month 1
Month 2
Month 3
Month 4
Month 5
Month 6
Month 7
Month 8
Month 9
Month 10
Month 11
Month 12
Pickup Assembly AO113457*
3 3 3 3 33 3 3 3 33 3 Vertical Leadscrew Leadscrew Grease
(in an SSR system) Apply a liberal coating of the grease to the sec-
tion of the screw between the collars above and
Pickup Assembly AO113457* below the motor
3 3 Vertical Leadscrew Leadscrew Grease
(in a PSS system)

Pickup Assembly AO113455* Apply a bead of lubricant along the entire length
3 3 3 3 Linear Bearings and Raceways Linear Bearing Grease of each “U” groove using wooded end of a Q-tip.

Pickup Assembly AO113457* Apply a liberal coating of the grease to the sec-
3 3 Horizontal Leadscrew Leadscrew Grease tion of the screw between the collars to the left
and right of the motor.

250-Plate Cassette Platform Lift AO113454* Remove top cover (6 screws). Apply a bead
3 3 Assembly Leadscrew Track Oil of lubricant along the entire length of screw.

Pinch Roller Cams and Wear Pads AO113456* Apply a liberal amount of the lubricant to
3 Cam Grease each cam and wear pad.

Pickup Assembly Rails AO113454* Apply a bead of lubricant along the entire
3 Track Oil length of each rail using a stiff brush.

99
 Pickup Assembly
The pickup assembly leadscrews, linear bearings and raceways
must be lubricated periodically as described in Table 2 on page 99.

VERTICAL HORIZONTAL
LEADSCREW LEADSCREW

LEFT RACEWAY*
for
VERTICAL
LINEAR BEARINGS

RACEWAYS
for
HORIZONTAL
LINEAR BEARINGS

* the RIGHT raceway, not shown

here, also must be lubricated.

Figure 4 - 6 Leadscrews and Linear Bearings & Raceways

100 AG45200 Rev. 2

 Pinch Roller Cams and Wear Pads
The pinch roller cams and wear pads must be lubricated
periodically as described in Table 2 on page 99.
The figure below shows the cam and wear pad at the left end of the
input roller. An identical cam and wear pad is on the right side of
the roller.
There is a cam and wear pad at either end of the output pinch roller.
INPUT
CAM PINCH ROLLER

WEAR PAD

Figure 4 - 7 Left Front Pinch Roller Cam and Wear Pad

Pickup Assembly Rail

The pickup assembly rails should be lubricated once a year as
described in Table 2 on page 99.

AG45200 Rev. 2 101

Clearing Misfeeds
If a misfeed occurs, the ERROR light comes on and prompts appear
on the control panel display to tell you what to do to correct the
problem.
The last prompt will be an instruction to press the OK button.

Step 1. Press the OK button. This turns off the blinking error
light, clears the error message from the display, and
initializes the platesetter.
Step 2. Resume normal operation.
Note: Sometimes a slip sheet or a plate failure is the result of a
problem in the cassette. If you follow directions to look
inside the autoloader but find no problems there, check the
contents of the cassette in a light safe environment.

Manually Lowering the Cassette Platform

The 250-plate cassette platform lift assembly has a manual control
for lowering the platform should the motor ever fail with the
cassette in the autoloader.
To manually lower the cassette platform:

Step 1. Obtain a 5mm or a 13/64” hex head socket wrench, and

a 6” (150 mm) extension.
Step 2. Insert the wrench w/extension through the hole at the
front of the lift assembly.
Step 3. Set the wrench on the 5 mm hex head shaft inside the
hole.
Step 4. Turn the shaft clockwise to lower the cassette plat-
form.
Step 5. Lower the platform enough to allow removal of the cas-
sette, but no more than that. If you lower the platform
too much, you could damage the lift assembly.

102 AG45200 Rev. 2

 Aligning the Platesetter and the Processor
It is very important for plates to travel along a level plane as they
move from the cassette, through the platesetter, and into the
processor. For that reason, it is critical that the height and level of
the plate processor, the platesetter, and the cassette cart be precisely
set and aligned, and in the following order.
• PLATE PROCESSOR
• PLATESETTER
• CASSETTE CART
Detailed instructions for aligning a system begin on the next page.
IMPORTANT NOTE
If two or more systems are operating at the site, make sure the
imaging plane height from the floor is the same for all systems.
Ideally, every system should have a level imaging plane that is
approximately 37-1/4 inches (96.6 cm) above the floor.

IMAGING PLANE

37-1/4 in.
Processor Platesetter Cart (96.6 cm)

FLOOR

Figure 4 - 8 System Imaging Plane

AG45200 Rev. 2 103

 Leveling the On-line Processor
Refer to the plate processor manufacturer’s documentation for
height and level adjustment procedures. Adjust the processor to
receive input at a height of 37.25 +/- 0.25 inches (94.6 +/- 6.3 cm).

Leveling the Platesetter

Step 1. Unplug the power cable from the power conditioner
outlet. Leaving one end of the cable plugged into the
platesetter, coil the cable and set it on top of the
transport unit.
Step 2. Disconnect the SCSI cable from the PC attached to the
platesetter. Leaving the SCSI cable connected to the pla-
tesetter, gently coil the power cable and store it on the
shelf in the pedestal.
AW3879-A

PLATESETTER
PLATE
PROCESSOR
CASSETTE
& CART

LEVELING
FEET

LEVELING
FEET
HEIGHT ADJUSTMENT
SHIMS
Figure 4 - 9 Level and Height Adjustments

104 AG45200 Rev. 2

 Step 3. Retract all four leveling feet so the system rides on its
wheels.
Step 4. Roll the system in its new location.
Step 5. Position the platesetter in front of the plate processor.
Step 6. Turn all four leveling feet of the platesetter down until
they just touch the floor.
Step 7. Turn all four leveling feet an additional 3 to 3.5 revolu-
tions to bring the machine up slightly.
Step 8. Adjust the back leveling feet as required to align the
media transport output slot with the plate processor
input slot, in both the horizontal and vertical planes.
Step 9. Set a spirit level on top of the autoloader and run it
lengthwise down the middle of the cover.
Step 10. Adjust the platesetter’s front leveling feet as required
until the front of the platesetter is level with the back, in
both the horizontal and vertical planes.
Step 11. Roll the cassette assembly to the front of the plateset-
ter.
Step 12. Position the cassette in front of the lift assembly, and
then push the cassette forward just enough to have the
guide rails at the bottom of the cassette make contact
with the input rollers on the lift assembly.
Step 13. Check the alignment of the cassette guide rails with
the lift assembly input rollers. The top of each guide rail
should contact the input roller at a point 1/4” (6.4 mm)

AG45200 Rev. 2 105

 to 5/8” (19.9 mm) below the top of the load roller (see
below).

LOAD ROLLER FRONT OF

CASSETTE
0”
1/8” 1/4”
5/8”

LIFT
ASSEMBLY
CASSETTE
GUIDE RAIL
TOP OF
INPUT ROLLER GUIDE RAIL

Figure 4 - 10 Cassette and Lift Assembly Alignment

Step 14. If the tops of the rails do not fall within the 1/4” (6.4
mm) to 5/8” (19.9 mm) range specified above:
a) Raise or lower both the front and back leveling
feet on the platesetter by an equal number of
turns (up to a maximum of 1.5 turns).
b) Recheck the alignment of the cassette rails to
the input rollers.
c) If the alignment is proper, you are finished.
d) If the cassette rails and input rollers are still out
of alignment, adjust the height of the cassette as
described below in ‘Adjusting the Height of the
Cassette’.

Leveling the Cassette Assembly

There is no need to level the cassette assembly. When the cassette is
loaded into the autoloader, the entire cassette assembly is raised up
onto the lift mechanism, which provides a level support for the
cassette assembly and suspends the assembly slightly above the
floor.

106 AG45200 Rev. 2

 The height at which the cassette assembly is suspended above the
floor depends on the contents of the cassette. For an empty cassette,
the back wheels of the cassette assembly will be about 1/4” above
the floor. For a full cassette, the back wheels will be close to or
possibly be barely touching the floor. However, this will only be
the case if:
• The platesetter is levelled as described above in this section.
• The cassette is at the factory-adjusted height.
• The floor is level.

Adjusting the Height of the Cassette

Step 1. Empty the cassette.
Step 2. Place a large cardboard sheet next to one side the cas-
sette assembly.
Step 3. Carefully turn the cassette assembly on its side, resting
it on the cardboard.
Step 4. Locate the height adjustment shims. There are four in
each corner. Each shim is 1/8” thick. By increasing or
decreasing the number of shims between the caster
mount and the side side panel, you can increase or
decrease height of the cassette cart by as much as 1/2”
(12.5 mm), in 1/8” (3.2 mm) increments.
Step 5. To increase the cart height 1/8” (3.2 mm) at each corner:
a) Loosen the shim mounting screws.
b) Remove one shim from the top of the caster mount and
set it between the caster mount and the side wall.
c) Tighten the shim mounting screws.

Step 6. To decrease the height 1/8” (3.2 mm), at each corner:

a) Loosen the shim mounting screws.
b) Remove one shim from between the caster
mount and the side wall and set it on top of the
caster mount.
c) Tighten the shim mounting screws.

AG45200 Rev. 2 107

 Step 7. Turn the cassette assembly upright.

Checking the Mist Separator

The air regulator assembly mounted to the bottom of the media
transport includes a mist separator (see figure below). Ocassionally
check the separator to see if any oil and/or water has accumulated
in the cylinder. If it has, loosen the cap shown below to drain the
fluid(s), replace the cap, and then troubleshoot the air filtration
system for your company’s air compresssor. It should prevent any
oil or water from ever reaching the platesetter’s air regulator.

AIR REGULATOR
ASSEMBLY

MIST
SEPARATOR
Note: If your system includes the
toggle switch shown here, do not
tamper with it. It is intended for
service personnel only.

DRAIN
CAP

Figure 4 - 11 Air Regulator Mist Separator and Drain Cap

108 AG45200 Rev. 2

Symbols Connections diagram, 16
53 Control panel
error messages, 46
A purpose of, 9
ATTENTION status messages, 45
PERIODIC MAINTENANCE IS OVERDUE Controller Board, identification of, 44
message, 45 Controller Board. identification of, 31
AUDIO ALERTS menu item 23 Counter, slip sheets, 84
Autoloader Cover interlocks
function of, 7 disabling, 31
Covers
B removing and replacing 48
BAR SPACING menu item 36 COVERS ARE NOT SECURE error 46
BAR WIDTH menu item 34 CtServer
functions 16
C manual for, 16, 40, 43
Cassette
capacity (250-plate cassette), 14 D
ID block coding, 15 DISPLAY ERROR LOG menu item 33
loading a PSS cassette, 59 Disposal bin
loading an SSR cassette, 66 capacity, 86
lock, 12, 14, 31 emptying, 84
safelight loading requirement, 1
types E
PSS 60-plate, 11 EJECTING PLATE message 45
SSR 250-plate, 13 ENABLE CASSETTE LOCK AFTER 5
SSR 60-plate, 11 SECONDS menu item 27
ENABLE SLIPSHEET COMPACTING menu
CASSETTE AND BIN CONTENT menu
option, 30
item 27
ENABLE USER ACCESS menu item 33
Cassette cart
ENGLISH option 23
250-plate 13
ENHANCED PLATE SEPARATION menu
60-plate 12
item 30
Cassette platform (250-plate)
Equipment configuration
manually lowering, 102
displays showing, 44
Chad container
Errors
emptying, 87
correcting 48
location of, 87
messages 46
Cleaning
ESTIMATED NUMBER OF JOBS PER MONTH
cassettes 96
menu item 26
fan filters 92
EXPOSING IMAGE message 45
input rollers 95
Exposure
output rollers 96
adjusting
Compactor 6
for photopolymer plates, 38
enabling/disabling, 30
functional description, 86 for silver plates, 43
location of, 6 EXPOSURE LEVEL menu item 37
malfuction, 30
precautions, 85 F
Time-out error message, 86 Fans, 92
Compressed air FEEDING PROCESSOR message 45
system requirements, 1 FETCHING PLATE message 45

AG45200 Rev. 2 109

Filtered fan, 92 notes for 250-plate cassette, 70
Firmware, 31, 44 notes for 60-plate cassettes, 65
Lock, cassette, 12
G Lubrication
Gap, alignment pin -to-plate 63 chart, 99
items needing, 98
H
Halted system, 10 M
Heat dissipation Maintenance
system, 1 determining when to perform, 33
HORIZONTAL MAGNIFICATION menu reminder messages on display, 26
item 38 Maintenance, see also "Cleaning" and
HORIZONTAL RESOLUTION menu item 36 "Lubrication"
Humidity Manually loading a plate, 82
operating range, 1 Media jams, 102
Media transport
I that uses a 24"-wide belt, 7
Identification label that uses narrow belts and rollers, 7
location of, 3 MENU key 20
IGNORE LASET TEMP ERRORS menu Menus
item 25 accessing, 22
IGNORE MISSING SLIPSHEET IN CASSETTE Test Patterns Menu 34
menu item, 25 User Maintenance Menu 31
IMAGE LENGTH menu item 36 User Preferences Menu 23
IMAGE OFFSET ERROR error 46 METRIC option 23
IMAGE OFFSET menu item 23, 25, 26, 36 Mist separator, 108
Imaging unit Model number
function of, 7 identification of, 6
INITIALIZING message 45 MONITOR DISPOSAL BIN FULL menu
Interlocks 48 option, 30
Ionizer bar Moving the system 104
location of, 98 MOVING TO PROCESSOR message 45
purpose of, 98 MULTIPLE PLATE PICKUP ERROR
SENSITIVITY menu item 29
J
Jobs, how to run, 17 N
NEXT Key 20
L NUMBER OF PLATES menu item 36
LANGUAGE menu item 23
Laser O
power of, 44 OK Key 21
LASER IS OVER TEMPERATURE error 46 ONLINE message 45
LED ONLY 1PIN BAR IN USE menu item 23
Attention (Yellow) 21 Operating parameters
Expose (Green) 21 setting, 22
Stop (Red) 21 OPERATOR ABORT error 46
Leveling Options
the platesetter 104 identifying, 6
the processor 104 OVERLAP OUTPUTTING & IMAGING menu
Loading cassettes item 26
see also "Cassette, loading ..." OVERSCAN menu item 24

110 AG45200 Rev. 2

P S
PERIODIC MAINTENANCE ALERTS menu SELECT Key 21
item 26 Serial number
PERIODIC MAINTENANCE menu item 33 identification of, 6
Permanent slip sheets, 11 Setting parameters, 22
Pin bar Shutting down the system, 19
for long plates, 10 Slip sheets
for short plates, 10 emptying discarded, 84
Pin Bar(s) see "Plates, Registration Pin Bars nominal thickness, 28
PLATE LENGTH menu item 38 SLIPSHEET THICKNESS menu item, 28
Plate punch Spinner motor 44
location of, 6, 10 Starting up the system, 17
PLATE SOURCE menu item 37 Step wedge test 38
Plate supply STOP Key 21
how the platesetter calculates, 52 System laser
inexact reporting of, 52 classification of, 2
PLATE THICKNESS menu item 37 Systems
PLATE WIDTH menu item 37 indentification of, 6
Plateline interface, 10
Plates T
acclimating to room temperature 59 Temperature
big vs. small, 28 operating range, 1
length/width orientations, 53 TEST PATTERN TYPE menu item 34
manual loading of, 82 Test Patterns Menu. 34
registration pin bars, 10 TEST PATTERNS message 45
sizes supported, 53 TEST PATTERNS MODE menu item 34
thicknesses supported, 53 Toggle switch, 108
types 53 Transport unit, 7
usage (number run per month), 26
Power conditioner U
function of, 16 UNITS OF MEASURE menu item 23
illustrtaion of, 8 USE CASSETTE ID’s menu option 27
Power cord receptical USE THE PLATELINE INTERFACE menu
location of, 9 item 25
Power switch USE TRANSPORT AS AN OUTPUT TRAY
controls DC only, 9 menu item 25
location of, 9 User Maintenance Menu, 31
Power-up sequence User Preferences Menu, 23
platesetter before workstation, 17
PREPARING TO EXPOSE message 45 V
PREVIOUS Key 20 VERTICAL MAGNIFICATION menu item 38
PROCESSOR SPEED menu item 26 VERTICAL RESOLUTION menu item 37
PROGRAM VERSION menu item 31
Punch, 6, 10 W
WAITING FOR LASER message 45
R Warm-up period, 17
RECORDING IMAGE message 45 Warning light
REGISTERING PLATE message 45 optional remote, 10
REVERSE IMAGE POLARITY menu item 36 top cover, 10
RUN MEDIA ROLLERS menu item 31 Weight
RUN TRANSPORT menu item 31 fully loaded 250-plate cassette, 14
Running a job, 17

AG45200 Rev. 2 111

Workstation 16
rebooting, 19

112 AG45200 Rev. 2