Fuji V6 Installation

LUXEL V-6 SERIES CTP INSTALLATION GUIDE

6800154011

FFEI Ltd.Block 2, Eaton Court

Eaton RoadHemel Hempstead

Herts, HP2 7DRUnited Kingdom

Tel: +44 01442 213440Fax: +44 01442 210579

www.ffei.co.ukRegistered Number: 3244452

©2007

PRELIMINARIES

IMPORTANT: FFEI Ltd products are so designed and constructed as to be safe without risk to health when properly used (in accordance with the supplied documentation) and when the safety precautions contained in this document are fully observed.

This manual must not be copied without prior written authorization and is subject to change without notice. For further information, contact FFEI Ltd at the address given on the front page of this manual.

WARNING: All precautions mentioned in this document must be strictly observed at all times. Personnel must read the contents of any documentation supplied and used with this product BEFORE commencing any work with equipment described in this document.

NOTE: Measured noise level for this product is less than 65 dBa.

CAUTION: FFEI Limited cannot be held responsible for any loss or damage to customer’s data by unauthorised third parties accessing the system. In the event that FFEI Ltd becomes aware of any computer virus which will or is likely to affect the system it will take reasonable steps to bring this to the attention of customers but advises customers to take their own precautions against unauthorised access.

TRADEMARKS and COPYRIGHT: Fuji and Fujifilm are trademarks of Fuji Photo Film Co., Ltd that may be registered in certain jurisdictions; Luxel, Celix, FineScan, Celsis, C-dot, C-Scan, Quattro, Lanovia, ColourKit and Celebrant are trademarks of FUJIFILM Corporation that may be registered in certain jurisdictions; Adobe, Accurate, PageMaker, Illustrator, PostScript, Pho-toshop and Type Manager are trademarks of Adobe Systems Inc. that may be registered in certain jurisdictions; Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries; all other company names, products or brand names are trademarks of their respective holders.

The manual was written and illustrated using the best possible information at the time of pub-lication. Any differences between the manual and equipment reflect improvements intro-duced after publication of the manual. Changes, technical inaccuracies and typographic errors will be corrected in subsequent editions. As part of our policy of continuous improve-ment, we reserve the right to alter design and specifications without further notice.

For installations with a nominal line voltage greater than 220 V and a frequency of 50 Hz: The equipment is intended for use in premises having a service current capacity of >= 100 A per phase. The user should determine in consultation with the supply authority, if necessary, that the service current capacity at the interface point (ie building entry) is sufficient for the equipment.

LUXEL V-6 SERIES CTP

Electromagnetic Compatibility Notice - USAThis equipment has been tested and found to be compliant 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 envi-ronment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, 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 their own expense.

Electromagnetic Compatibility Notice - EuropeThis product has been found to satisfy the Class A limits for a radio interface of information tech-nology equipment. Class A equipment is intended for use in a light industrial or commercial en-vironment for which the 30 metre protection distance is used. Operation of this equipment in a domestic or residential environment may result in interference to other equipment, in which case the user will be required to correct the interference at their own expense. In some coun-tries this equipment may be subject to restrictions on its use. Where applicable the user should inform the relevant local authority that Class A Information Technology Equipment has been taken into service.

This equipment may also be susceptible to strong electromagnetic fields and should not be sit-ed close to high power radio transmitters or radio installations. If the intended site of operation is prone to electromagnetic disturbances due to lightening strikes, additional precautions should be taken to protect the equipment from the resulting electromagnetic disturbance. Typ-ical examples for the intended environment of this equipment would include:

• business premises, for example, offices, banks, etc.

• retail outlets, for example, shops, supermarkets, etc.

• light industrial locations, for example, workshops, service centres, etc.

Locations which are characterised by being supplied directly at low voltage from the public mains are considered to be residential, commercial or light industrial.

This equipment conforms to the requirements of EC directives:

• 73/23/EEC - Low Voltage Directive

• 89/336/EEC - EMC Directive.

PRELIMINARIES

About this ManualThis manual describes how to install one of the following Luxel Computer-to-Plate (CTP) systems after an on-site pre-installation check has been completed.

• Luxel V-6e: Manual and Semi-Automatic.

• Luxel V-6: Manual, Semi-Automatic and Fully-Automatic Single-Cassette (SAL) with and without manual load slot (MLS).

• Luxel V-6: Fully-Automatic with Multi-Cassette Autoloader (MAL).

Engineers are recommended to refer to the safety practice information in Chap-ter Two before starting the installation.

Procedures in this manual should only be carried out by engineers who have attended an approved FFEI Luxel platesetter engineering course.

Information in this manual is for installing software at PHASE 11 onwards.


TABLE OF CONTENTS

Chapter 1 Introducing the Luxel V-6 Series

The Luxel V-6 Series CTP System .......................................................... 1-1

Luxel V-6e Manual and Semi-Auto..................................................... 1-2

Luxel V-6 Manual ....................................................................................... 1-3

Luxel V-6 Semi-Automatic ...................................................................... 1-4

Luxel V-6 Single-Cassette (SAL) ............................................................. 1-5

Luxel V-6 CTP Multi-Cassette (MAL) Autoloader ............................ 1-7

Network Connections ................................................................................ 1-8

Loading Applications and Options ...................................................... 1-9

Completing the Installation Report .................................................... 1-9

Chapter 2 Safety on the Luxel V-6

Health and Safety at Work ..................................................................... 2-1

Warnings and Cautions ........................................................................... 2-2

Clothing and Jewellery ............................................................................ 2-2

Equipment and Tools ............................................................................... 2-2

Site Safety Rules ......................................................................................... 2-2

Safety Labels and Indicators................................................................... 2-3

Mains Rating Label ................................................................................... 2-3

Drum and Traverse Warning Labels .................................................... 2-4

Autoloader Warning Labels................................................................... 2-5

Autofeeder Warning Labels .................................................................. 2-5

Optics Warning Labels ............................................................................. 2-9

Electrical Warning Labels........................................................................ 2-10

PRELIMINARIES

Interlock Warning Labels.........................................................................2-11

Safety Devices ..............................................................................................2-14

Unattended Equipment ...........................................................................2-14

Dust Prevention ..........................................................................................2-14

Plate Handling.............................................................................................2-14

Electrical Safety...........................................................................................2-15

Mechanical Safety ......................................................................................2-15

Spinner Safety .............................................................................................2-16

Moving Parts Safety ..............................................................................2-16

Acoustic Noise Safety ...........................................................................2-16

Safety Interlock System .............................................................................2-16

Interlocked Covers .....................................................................................2-16

Locked Covers ..............................................................................................2-19

Interlock Over-rides ...................................................................................2-19

Laser Safety .....................................................................................................2-21

Laser Precautions........................................................................................2-22

Laser Safety Shutter ..................................................................................2-22

Laser Safety Warnings ..............................................................................2-23

A DLA Room ............................................................................................2-24

A DLA Curtain .........................................................................................2-24

Chapter 3 Unpacking and Handling

Unpacking the Equipment.......................................................................3-1

Consignment Check...................................................................................3-1

Inspection of Boxes....................................................................................3-2

Unpacking the Modules...........................................................................3-3

Unpacking the Processor .........................................................................3-6


Handling the Equipment ......................................................................... 3-6

Using a Fork-Lift......................................................................................... 3-7

Chapter 4 Installing Luxel Equipment and Soft-ware

Start the Installation .................................................................................. 4-1

Special Tools Required ............................................................................. 4-1

Pre-Install Checks ....................................................................................... 4-2

Check Floor Gradient ........................................................................... 4-2

Remove the Module Covers ................................................................... 4-3

Remove V-6 Engine Top Cover ......................................................... 4-5

Remove V-6e Engine Top Cover (Manual) ................................... 4-5

Remove V-6e engine Top Cover (Semi-Auto).............................. 4-6

Heavy Lifting Operations ........................................................................ 4-6

Installation Sequence ............................................................................... 4-7

Semi-Automatic (Luxel V-6e) ............................................................ 4-7

Semi-Automatic (Luxel V-6)............................................................... 4-7

Single-Cassette Fully-Automatic (Luxel V-6) ................................ 4-8

Multi-Cassette Autofeeder (Luxel V-6) .......................................... 4-9

Install the Processor.................................................................................... 4-9

Install the Engine......................................................................................... 4-10

Remove Engine Transit Fixings ............................................................. 4-10

Traverse Carriage Transit Fixing....................................................... 4-10

Platen Transit Fixings (V-6 Only) ...................................................... 4-12

Integrate the Processor and Engine .................................................... 4-13

Set the Processor Height .................................................................... 4-13

Mate the Engine to the Processor................................................... 4-13

Level the Engine ........................................................................................ 4-15

PRELIMINARIES

Manual System .......................................................................................4-15

All Variants ..............................................................................................4-16

Install the Autoloader (Luxel V-6) ........................................................4-17

Remove Autoloader Transit Fixings .....................................................4-17

Remove the MLS Transit Fixings .......................................................4-19

Mate the Autoloader and Engine ........................................................4-21

Level the Trolley and Cassette ...............................................................4-24

Set the Second Trolley Height ...............................................................4-28

Install the Multi-Cassette Autofeeder (MAL) .................................4-28

Integrate and Level the Autofeeder (Basic Level) ..........................4-29

Connect the Autofeeder Cables ............................................................4-33

Remove Transit Fixings Using the Brake Override..........................4-37

Set up the Brake Override ..................................................................4-38

Lower the Elevator................................................................................4-40

Raise the Elevator ..................................................................................4-40

Remove the Brake Override...............................................................4-40

Remove the Transit Fixings .....................................................................4-40

Integrate and Level the Autofeeder (Fine) .......................................4-43

Levelling the Trolley..................................................................................4-46

Set up the System.........................................................................................4-48

Align Carriage and Ball Cage .................................................................4-48

Connect Power and Equipment ............................................................4-49

Attach the PAT Air Filtering System ....................................................4-51

Connect the Vacuum Pump ....................................................................4-52

Connect the Processor Earth Cable ......................................................4-53

G&J Earth Cable Fitting .......................................................................4-53

Heights (Inca) Earth Cable Fitting ....................................................4-55

Fitting the PC G10 Film Filter .................................................................4-55

Final Visual Checks .....................................................................................4-55


Plate Output Alignment Checks ...................................................... 4-55

Clean Engine Drum ................................................................................... 4-57

Install Luxel Desktop Applications and Device Driver ............... 4-58

System Pre-Requirements ....................................................................... 4-58

Installing the LuxelServer ....................................................................... 4-59

Install the LuxelServer (Device Drivers) .............................................. 4-59

Install the LuxelDesktop .......................................................................... 4-59

Installing Licence Options and Upgrades ........................................ 4-59

Obtaining Licence Keys ........................................................................... 4-60

Chapter 5 Commissioning the Luxel V-6 System

Start to Commission the Platesetter................................................... 5-1

Initial Software Checks and Setups..................................................... 5-2

Open Main Diagnostics and Check Engine Clock ........................... 5-2

Check Power Supply Voltages ............................................................... 5-3

Check Cover Interlocks............................................................................. 5-4

Check Engine Traverse Level.................................................................. 5-5

Set up the Processor (if Installed)......................................................... 5-7

Setting up Optics and Imaging ............................................................. 5-8

Check Beam Focus ..................................................................................... 5-8

Calculating Values for 96 Resolution Test Strips ............................ 5-12

Calculating Values for 48 Resolution Test Strips ............................ 5-14

Calibrate for Laser Exposure.................................................................. 5-15

MMI Menus (Luxel V-6) ....................................................................... 5-15

PCI Menu (Luxel V-6e) ......................................................................... 5-17

Check Registration and Tint Quality ................................................... 5-17

PRELIMINARIES

Check Plate Registration .....................................................................5-18

Expose a 50% Prediction Test Plate ................................................5-18

Test Image Quality ...............................................................................5-20

Check Edge Detect Function ..................................................................5-20

Checking Plate Output (without a Punch).......................................5-21

Check Image Skew Accuracy ..................................................................5-21

Check Image Base and Edge Accuracy ................................................5-22

Set Image Base Offset ..............................................................................5-23

Set Image Edge Offset .............................................................................5-24

Checking Plate Output (with a Punch) ..............................................5-25

Punch Configuration Check ....................................................................5-25

Check Image to Top of Plate Accuracy ...............................................5-27

Check Image to Punch Crop Accuracy.................................................5-28

Check Image Base Position in RIP .........................................................5-29

Check for Image Centering .....................................................................5-29

Installing the Remote Alert Forwarding ...........................................5-30

Preliminaries ................................................................................................5-30

Setup the Mail Configuration ................................................................5-31

Local Mail Server:...................................................................................5-32

Web-Based Mail Servers ......................................................................5-32

SMTP Authentication ...........................................................................5-32

Web-Based Mail Host ...........................................................................5-33

POP Authentication ..............................................................................5-33

Configure the Alert System ....................................................................5-35

Chapter 6 Demonstrating the Luxel V-6 System

Demonstrate the Platesetter ..................................................................6-1

Platesetter Safety and Interlocks ..........................................................6-2


Laser Safety.................................................................................................. 6-2

Electrical Safety .......................................................................................... 6-2

Mechanical Safety ..................................................................................... 6-2

Accessing the Platesetter ........................................................................ 6-2

Using the MMI (V-6 Option) and PCI ................................................. 6-2

Platesetter Maintenance.......................................................................... 6-3

Emptying the Chad Tray (Luxel V-6 with Punch) ............................ 6-3

Emptying the Interleaf Bin (Single- and Multi-Cassette) ............. 6-3

Cleaning the Spinner Mirror.................................................................. 6-3

Checking the Platesetter Environment .............................................. 6-3

Vacuum Clean the Platesetter............................................................... 6-3

Recovering From Platesetter Errors .................................................... 6-4

Operator Recovery From Media Jams................................................. 6-4

Recovery From System Errors ............................................................ 6-4

Loading Cassettes (Single- and Multi-Cassette) ........................................................................................ 6-5

Running the RIP............................................................................................ 6-5

Switching On/Off Sequence ................................................................... 6-5

Calibrating the Platesetter Output ..................................................... 6-5

Ordering New Options ............................................................................ 6-5

PRELIMINARIES

INTRODUCING THE LUXEL V-6SERIES

1.1 The Luxel V-6 Series CTP SystemThis installation manual explains how to install the following Luxel B2 family of platesetters fitted with Violet laser optics and supplied options:

Luxel V-6e CTP Manual and Semi-Automatic system: See Sec-tion 1.1.1 on Page 1-2

Luxel V-6 CTP Manual system: See Section 1.1.2 on Page 1-3.

Luxel V-6 CTP Semi-Automatic system: See Section 1.1.3 on Page 1-4.

Luxel V-6 CTP Single-Cassette Autoloader system (SAL) with and without Manual Load Slot (MLS): See Section 1.1.4 on Page 1-5

Luxel V-6 CTP Multi-Cassette Autoloader (MAL system: See Sec-tion 1.1.5 on Page 1-7.

This chapter describes the main equipment modules of the Luxel V-6 and V-6e platesetters.

1.1 The Luxel V-6 Series CTP System ...................................................... 1-11.2 Network Connections........................................................................... 1-8

1-2 INTRODUCING THE LUXEL V-6 SERIES

NOTE: Before starting a Luxel installation, the site should be assessed by a Distributor representative for all site require-ments described in the Luxel V-6 Series CTP Pre-Installation Guide.

1.1.1 Luxel V-6e Manual and Semi-AutoA typical Manual Luxel V-6e platesetter is illustrated in Figure 1.1 on Page 1-2.

Figure 1.1 Luxel V-6e: manual

A Luxel V-6e comprises the following equipment and modules:

Engine with I/O load platen.

Processor (semi-automatic only).

PAT Air Filter.

Vacuum pump (external manufacturer supply).

RIP/PCI PC (supplied separately by the customer).

RIP application software with the options of:

INPUT/OUTPUTLOAD PLATEN

LUXEL V-6 SERIES CTP 1-3

Celebrant

Gateway

Rampage.

PCI (Dashboard) application - see Installation Notes with PCI software.

1.1.2 Luxel V-6 ManualA typical manual V-6 platesetter system is illustrated in Figure 1.2 on Page 1-3.

Figure 1.2 Luxel V-6: manual

It comprises the following equipment and modules:

Engine with input platen.

PAT Air Filter (external manufacturer supply).

Vacuum pump.

RIP/PCI PC (supplied separately by the customer).

RIP application software with the options of:

Celebrant.

ENGINEINPUT

PLATEN


Gateway.

Rampage.

PCI (Dashboard) application - see Installation Notes with PCI software.

1.1.3 Luxel V-6 Semi-Automatic A typical semi-automatic Luxel platesetter system is illustrated in Figure 1.3 on Page 1-4.

Figure 1.3 Luxel V-6: semi-automatic

It comprises the following equipment and modules:

Engine with input platen.


Vacuum pump.

Processor (external manufacturer supply).

Stacker (external manufacturer supply).

RIP/PCI PC server (supplied separately by the customer).

INPUT PLATEN

ENGINE PROCESSOR


RIP application software with options of:

Celebrant

Gateway

Rampage.

PCI (Dashboard) application - see Installation Notes with PCI software CD.

1.1.4 Luxel V-6 Single-Cassette (SAL)A typical single-cassette Luxel V-6 platesetter without a Manual Loading Slot (MLS) is illustrated in Figure 1.4 on Page 1-5. A V-6 with MLS is shown in Figure 1.5 on Page 1-6.

Figure 1.4 Luxel V-6: single-cassette (without MLS)

A single-cassette comprises the following equipment and mod-ules:

ENGINE

AUTOLOADER

TROLLEY/CASSETTE

PROCESSOR


Engine.

Autoloader with MLS option.

Trolley with cassette (one trolley supplied as standard with the option ofup to five).


Vacuum pump.




Figure 1.5 Luxel V-6: single-cassette (with MLS)

RIP application software with options of:

Celebrant

Gateway

Rampage.

PCI application (see Installation Notes with PCI software CD).

MANUAL LOAD SLOT


1.1.5 Luxel V-6 CTP Multi-Cassette (MAL) Autoloader

A typical multi-cassette autoloader Luxel V-6 platesetter with an autofeeder module is illustrated in Figure 1.6 on Page 1-7.

Figure 1.6 Luxel V-6: multi-cassette (MAL)

A multi comprises the following equipment and modules:

Engine.

Autoloader.

Autofeeder.

Trolley and cassette (one trolley and two cassettes is supplied as standard with the option of up to seven cassettes). The standard trolley has a fixed platen. An optional tilt trolley has an adustable platen to allow passage through narrow door-ways.


Vacuum pump.


AUTOLOADERAUTOLOADER

AUTOLOADERAUTOFEEDER




1.2 Network ConnectionsA typical networked system is shown in Figure 1.7 on Page 1-8.

Figure 1.7 Luxel V-6 networked configuration: semi-automatic

Network connections for all Luxel V-6 series platesetters are based on:

PCI/RIP PC

(ETHERNET/TCP/IP)

IMAGE DATA/ENGINE CONTROL(FIREWIRE)

IMAGES FROMDESKTOP SYSTEMS *

RIP S/W

DIAGNOSTICDATA

(RS232)

ENGINE

PLATEPROCESSORSTACKERNOTSHOWN

* SEE YOURRIP USER'S GUIDE/PRE-INSTALLATION GUIDE

PROCESSORCOMMS

PCI S/W

ENGINE F/W


1. Ethernet (or any suitable network): from the RIP PC to DTP sys-tems (see documentation supplied with network equipment).

2. FireWire link (IEEE-1394): between the Engine and the RIP/PCI server for downloading RIP image data and controlling plate-setter output.

3. Serial link (RS232): from the Engine to the RIP/PCI server or any terminal with HyperTerminal for accessing platesetter diag-nostics.

4. RS232 link: from the Engine to the Processor.

NOTE: There is no communication link between the Processor and the Stacker. The Stacker operates when it senses an ejected plate.

1.2.1 Loading Applications and OptionsThe Luxel V-6 system is shipped and tested with the following software with Release Notes available on SIO:

1. Firmware: A set of backup CDs holding the installed firmware also contain useful Release Notes with required NVRAM data for different machine configurations.

2. LuxelDesktop: this software is loaded on the RIP PC as part of the installation.

Two types of remote alert systems for indicating the status of engine errors are available:

1. Remote Alert: a local beep or flashing system with informa-tion in the Pre-Installation Guide.

2. Remote Alert Forwarding: the engine sends error reports as text to a remote PC or mobile address, see Section 5.6 on Page 5-30.

1.2.2 Completing the Installation ReportIMPORTANT: After the platesetter has been commissioned and accepted by the customer, complete the Installation Report to ensure the site configuration is fully supported by FFEI (UK).


SAFETY ON THE LUXEL V-6

NOTE: Information in this section applies to the Luxel V-6 and Luxel V-6e.

2.1 Health and Safety at WorkAll personnel are advised to familiarize themselves with any local or national legislation relating to health and safety at work. Par-ticular attention should be given to those sections covering per-sonal responsibility regarding safe working practices which must be strictly observed at all times.

This chapter explains the safety conventions used in this manual and highlights safety practices specific to the product.

To ensure a safe installation, engineers should follow the safety practice recommendations in this chapter. Only FFEI-trained and authorised engi-neers should complete a Luxel V-6 and V-6e installation.

2.1 Health and Safety at Work ................................................................... 2-12.2 Safety Labels and Indicators............................................................... 2-32.3 Safety Interlock System..................................................................... 2-162.4 Laser Safety ........................................................................................ 2-21

2-2 SAFETY ON THE LUXEL V-6

2.1.1 Warnings and CautionsThere are two safety categories given in this manual:

WARNINGS are given for conditions which may endanger life.

WARNING: The instructions given in warnings must be followed pre-cisely. They are given to avoid injury or death.

CAUTIONS are given for conditions which may cause damage to equipment or materials.

CAUTION: The instructions given in cautions must be followed to avoid damage to equipment or materials.

2.1.2 Clothing and JewelleryDo not wear clothing or jewellery which could be hazardous when in contact with any part of the equipment, or which could reflect laser light into the eyes.

2.1.3 Equipment and ToolsUse the approved service tools and the protection equipment required for laser and mechanical safety.

2.1.4 Site Safety RulesMost accidents can be avoided if you follow these simple rules.

Familiarize yourself with the location of mains supply On/Off switch on the engine and all other equipment On/Off switches.

Always obey the warnings, cautions, and any other instruc-tions included in this manual, and in other relevant equipment manuals associated to the equipment.

Never attempt to perform procedures that are not included in this manual.


2.2 Safety Labels and IndicatorsSafety labels are fitted to the equipment to warn you of potential hazards. These labels must not be defaced or removed. Typical warning labels, fitted within the platesetter, are shown in Figure 2.2 on Page 2-4 to Figure 2.11 on Page 2-13.

2.2.1 Mains Rating LabelSee Figure 2.1 on Page 2-3.

Figure 2.1 Mains input and rating label (Manual and Semi-Auto)

Volts:

Model No:

CERTIFIED TOCAN/USA STD C22.2 NO. 60950

ETL LISTEDCONFORMS TOUL STD 60950

CLASS 1 LASERLASER KLASSE 1

LASER DE CLASSE 1

FFEI LTD.PETERBOROUGHENGLAND

This laser conforms to the applicable requirements of21 CFR Sub chapter J.

2. This device must accept any interference received including interference that may cause undesired operation.

1. This device may not cause any harmful interference

This device complies with Part 15 of the FCC rulesand is subject to the following two conditions:

Product:

Serial No:

Max Current:

Manufactured:

and

50 / 60Hz ~

7550 854D 05

230

INTERTEK

LISTED

This Class A digital apparatus complieswith Canadian ICES-003.

Cet appareil numerique de la classe Aest conforme a la norme NMB-003 du Canada.

92206

C US

V6ENGINEM

10A

IMAGING ENGINE(REAR)

LUXEL V-6 HD

FULLY-AUTOMATICRATED AT 15 A


2.2.2 Drum and Traverse Warning LabelsFigure 2.2 on Page 2-4 illustrates the laser and spinner risks to the engineer on the user side after the cover is removed and the interlocks are defeated.

Figure 2.2 Drum: moving parts and edge detect warning labels

LASER RADIATIONAVOID DIRECT EYE EXPOSURECLASS 2R LASER PRODUCT0.8mW 635nm CW

IEC 60825-1 Amendment 2 / 2001


2.2.3 Autoloader Warning LabelsFigure 2.3 on Page 2-5 shows a moving parts label on the PTM feed head

Figure 2.3 Plate feed moving parts

2.2.4 Autofeeder Warning LabelsFigure 2.4 on Page 2-6 to Figure 2.7 on Page 2-9 show the warn-ing labels on the Autofeeder.


Figure 2.4 Autofeeder: elevator motor warning labels

WARNINGENSURE MAINS SUPPLY DISCONNECTED

BEFORE SERVICING


Figure 2.5 Autofeeder: elevator warning label


Figure 2.6 Autofeeder elevator moving parts warning labels

USER SIDE

SERVICE SIDE


Figure 2.7 Autofeeder: earth wire safety label

2.2.5 Optics Warning LabelsFigure 2.8 on Page 2-10 shows the areas of risk for the engineer from exposed laser beams when the optics base lid is removed.

AUTOFEEDER


Figure 2.8 Optics base: laser warning labels

2.2.6 Electrical Warning LabelsFigure 2.9 on Page 2-11 shows the area of risk from high-tension voltage inside the interlock box.


Figure 2.9 Interlock box: high-tension warning label

2.2.7 Interlock Warning LabelsFigure 2.10 on Page 2-12 (V-6e) and Figure 2.11 on Page 2-13 (V-6) shows the areas of laser beam risk to the engineer when the interlocked covers are opened and the interlocks are defeated.

Hochspannung

haute tensionPrecaucion!

caution!

orsicht!high tension

Attention!

V

Preé

óalta tensioón

T2A H 250V


Figure 2.10 Interlock defeated warning labels: typical Luxel V-6e


Figure 2.11 Interlock defeated warning labels: typical Luxel V-6


2.2.8 Safety DevicesRead all warning labels. Make sure that all safety controls, such as those listed below, are present and working correctly:

Circuit breakers.

Covers and doors.

Guards.

Panel indicators.

Safety interlocks.

WARNING: Unless essential for commissioning, and under prescribed conditions, never override, negate, or bypass any of the above safety devices.

2.2.9 Unattended EquipmentNever leave equipment unattended unless in a safe condition with respect to the following hazards:

Electrical.

Mechanical.

Laser Radiation.

Chemical.

2.2.10 Dust PreventionTo avoid dust contamination of the machine, it is important to restrict to a minimum any operation with covers, lids or doors removed or open.

2.2.11 Plate Handling

CAUTION: When handling plates, there is a risk of injury from sharp metal. Always wear suitable gloves while loading plates into a cassette, or removing plates from the platesetter.


2.2.12 Electrical SafetyRegularly verify that mains supply cables are not worn or dam-aged.

Make sure that water and other liquids do not come into con-tact with the equipment.

Do not attempt to operate the equipment when flammable or volatile substances are present in the atmosphere.

Avoid leaving electrical cables trailing where anyone may trip over them.

2.2.13 Mechanical SafetyThe following basic precautions apply to the platesetter system when the safety interlocks are over-ridden.

Always close and lock equipment access covers to prevent internal access on the service side of the engine and autoloader.

The platesetter consists of assemblies that are excessively heavy for one engineer to lift. If a replacement or installation procedure requires that one of these assemblies needs to be moved or lifted at any point, then make sure assistance is available. Information in the chapter will tell you if an assem-bly is more than a one-person lift.

WARNING: Do not attempt to lift heavy equipment or assemblies by yourself.

The platesetter has a number of motor-driven moving parts that could present a risk to the engineer. Make sure you are familiar with the main areas of danger listed below when the interlocks are over-ridden.

A) spinner

B) media handling assemblies (rollers)

C) plate pullbar

D) punch.


The exact position of the cassette is always noted by the machine software during normal operation. If the position of the cassette is changed by hand then serious damage could result. Note the following Caution:

CAUTION: After moving a cassette forward manually from the autofeeder to the autoloader ALWAYS make sure that the cas-sette is returned to the autofeeder before switching on the sys-tem.

2.2.14 Spinner Safety

2.2.14.1 Moving Parts SafetyWhile the interlocks are over-ridden, a high-speed spinner mirror presents a danger for the engineer.

NOTE: Note that even when rotating at an idle speed the spinner can appear in a halt state.

WARNING: The spinner rotates at very high speeds and can cause seri-ous injury if accidentally touched. Make sure the spinner has stopped rotating before accessing a drum with the interlocks defeated.

2.2.14.2 Acoustic Noise SafetyWhile the spinner is running and the covers on the engine are removed, there is an acoustic hazard of over 65 dB noise.

2.3 Safety Interlock SystemThe platesetter system includes a Category 3 safety control facility for protecting the operator and engineer from mechanical, laser and electrical hazards. A description of the interlock system is in the Luxel V-6 Series Engineer’s Reference Guide.

2.3.1 Interlocked CoversFigure 2.12 on Page 2-17, (Luxel V-6e) and Figure 2.14 on Page 2-19 (Luxel V-6) show the location of the interlocked covers.

WARNING: If the platesetter has to be run with a cover open and the


interlocks over-ridden, extreme care must be taken to avoid the follow-ing hazards: rotating spinner, laser beam, moving plate motors.

Figure 2.12 Location of interlock covers: Luxel V-6e manual

1


Figure 2.13 Location of interlock covers: Luxel V-6 single-cassette

2

1


Figure 2.14 Location of interlocked cassette door: Luxel V-6 multi-cassette

WARNING: All unqualified personnel must be prohibited from the area, while the machine is in the over-ridden state.The Laser Safety Officer must be informed when the machine is in this state.

2.3.2 Locked CoversAll screw-locked covers are shown in Figure 4.2 on Page 4-4. After completing the installation, make sure that the removed covers are securely locked again. This is to ensure that the operator can only access plates from the doors and covers shown in the User’s Safety Guide.

2.3.3 Interlock Over-ridesInterlocks are defeated by inserting the approved engine actua-tor key into the interlock switch shown in Figure 2.15 on Page 2-20 (engine) and Figure 2.16 on Page 2-21 (autoloader). Operating an over-ridden system allows the platesetter to generate a laser

3


beam, rotate the spinner and move the plate drive motors.

Figure 2.15 Fitting the interlock over-ride key: Luxel V-6 and V-6e engine

ENGINE FRAME

DOORSWITCH

OVERRIDEKEY


Figure 2.16 Fitting the interlock over-ride key: Luxel V-6 autoloader

While the key is in the switch, it is impossible to shut the inter-locked door and cover to prevent the engineer from leaving the machine with the interlocks defeated.

2.4 Laser Safety

CAUTION: Use of controls or adjustments, or performance of procedures other than those specified in this manual, may result in hazardous radiation exposure.

The Luxel CTP is labelled as a Class I laser product when all the covers are closed. When the covers are opened and the interlocks defeated, the machine is a Class IIIB laser source.

Light is emitted in the violet spectrum at 405 nm for imaging. Maximum power output from this laser source is Class IIIB.

AUTOLOADER SERVICE SIDE

INTERLOCKSWITCH

INTERLOCKOVERRIDE

KEY

TO OVERRIDE:INSERT KEY ANDTWIST CLOCKWISE

TO REMOVE KEY:TWIST ANTI-CLOCKWISEAND REMOVE


Light from the edge detect laser is in the red spectrum at 635 nm for plate edge detection. Maximum power output is 0.8 mW.

2.4.1 Laser PrecautionsLaser power is set at the factory from the NVRAM parameters supplied with the laser. Make sure that you:

Do not power up the platesetter with a laser disconnected.

Never place a mirror or other reflective material in the laser beam. This action can reflect hazardous light to others work-ing in the general area.

Remove the protective lid of the optics base only in accord-ance with the instructions given in the service procedure.

Wear attenuating laser safety goggles where there is a risk of direct reflection from a laser beam. If there is no such danger, or when observing diffused reflected spots from screens and targets, it is permissible to work without attenuating laser safety goggles.

2.4.2 Laser Safety ShutterA laser beam shutter, shown in Figure 2.17 on Page 2-23, is located on the optics base at the user end. The shutter is closed as a precaution against the beam entering the drum during a service procedure.

The beam can also be switched off using the diagnostics com-mand:

diagnostics/service/optics/laser/ldisable


Figure 2.17 Optic base shutter

2.4.3 Laser Safety WarningsLaser light, because of its special properties, poses safety hazards not associated with other light sources. The use of lasers requires that all service engineers and everybody near the laser system, are aware of the dangers involved. Laser safety depends on the engi-neer being familiar with the instrument and the properties of coherent, intense beams of light.

Note the following laser radiation warning:

WARNING: Never look directly into a laser beam. This could cause seri-ous damage and possible blindness.When working on a Class IIIB laser source, always wear goggles capa-ble of attenuating the beam to a Class II level if there is the slightest risk of direct reflection.The voltages used in the laser circuits, and power supplies, are poten-tially hazardous. Exercise extreme caution while servicing the plateset-ter with its interlocked covers removed.Protective cover around the laser beam must always be in place during normal scanning or test operations.

Laser beams can ignite volatile substances, such as alcohol or other solvents and damage light-sensitive elements in, for

OPTICS BASE(USER END)

OPEN

CLOSED

SHUTTER


instance, photodiodes. Reflected beams can also cause damage.

Laser safety warnings must at all times comply with local and national regulations.

While the laser is being serviced, it may be necessary to operate the platesetter with certain covers removed and the safety inter-locks over-ridden using the approved method. Under these cir-cumstances, only the installation engineer should be in the Designated Laser Area (DLA). The DLA may be a room, a cur-tained area, or a purpose-built DLA tent.

2.4.3.1 A DLA RoomAll other personnel should be warned of the hazard by:

A laser warning notice attached to the door(s) leading to the room. An example is shown in Figure 2.18 on Page 2-25.

A red warning light, positioned above the door(s) leading to the room, illuminated whenever there is a laser radiation haz-ard.

2.4.3.2 A DLA CurtainLocal legislation may permit the following alternative:

Isolation of the platesetter by means of a curtain. The curtain must be opaque to violet light and must extend from floor to a height of at least 2.1 m (82.7 in).

Warnings placed, where required, to ensure that personnel are aware of the laser radiation hazard inside the curtained area. The signs shown in Figure 2.18 on Page 2-25 are recom-mended.


Figure 2.18 Typical laser warning signs

NO ENTRY TO UNAUTHORISEDPERSONNEL

WHEN WARNING LIGHT IS ON

LASER CLASS 3B OPERATIONS

NO ENTRY TO UNAUTHORISEDPERSONNEL

WHEN WARNING LIGHT IS ON

LASER CLASS IIIb OPERATIONS

U.S.A.

EUROPEAN


UNPACKING AND HANDLING

NOTE: Information in this section applies to the Luxel V-6e and Luxel V-6.

3.1 Unpacking the Equipment

3.1.1 Consignment CheckThe local engineer or agent must ascertain, from a FFEI-compiled list or the shipper's consignment note, that the consignment is correct. Any deficiencies must be reported immediately.

Depending on the ordered Luxel configuration, a typical consign-ment comprises a set of boxes containing the following items:

Engine (all variants)

Autoloader (single-cassette)

Autofeeder (multi-cassette)

Trolley and Cassette

This section describes how to unpack and move Luxel V-6e and V-6 modules to their working positions.

3.1 Unpacking the Equipment ................................................................... 3-13.2 Handling the Equipment ...................................................................... 3-6

3-2 UNPACKING AND HANDLING

Stacker (if ordered)

Processor (semi- and fully-automatic)

PAT Air Filter (all variants)

Installation Pack (all variants) - see Table 3.1 on page 3-5.

Dimensions and weights of the packed modules for all variants is given in the Luxel V-6 Series CTP Pre-Installation Guide.

NOTE: The processor, stacker and PAT are shipped with their original manufacturer packaging.

3.1.2 Inspection of BoxesAll packaged equipment must be inspected at the customer's site by an engineer or an agent before unpacking begins. There are two Tip-n-Tell and two Drop-n-Tell indicators fitted to the outside of the box and the engine itself. The following steps are taken when there has been damage, corrosion, or positive Tip or Drop indications, see Figure 3.1 on Page 3-3 below.

1. Record the observations on the delivery documentation.

2. Inform the carrier, shipping agent and insurance agent.

3. Record the observations on the FFEI Installation Report.

NOTE: If the Tip or Drop indicators on the Engine are not tripped then the Engine has not been affected.

Units may be removed from their box only by an approved engi-neer or representative. If there has been damage during shipping, unpacking will have to be delayed. Do not proceed with unpack-ing until authorized by the shipping and insurance agents.

NOTE: Markings on the box indicate which side is the front of the module.


Figure 3.1 Mishandling indicators

3.1.3 Unpacking the Modules

CAUTION: Two people are required to manoeuvre the engine while it is supported by castors. The module is very heavy and includes delicate items of equipment.

CAUTION: Modules should be left for a 24 hours acclimatisation period in their operating temperature and humidity environment before the vacuum barrier seal is removed.

Unpack each box using the instructions attached to the outside of the box. A typical unpacking method for a FFEI module is as fol-lows:

1. Locate the box in a position where there is enough room to unpack and fork-lift the module from its box.

2. Cut any bands securing the box.

3. Lift off the cardboard top cap (two-man lift).

4. Remove any top protective foam inserts and lift off the box sleeve to reveal the module on a wooden palette base.

5. Check that the foil vacuum seal surrounding the module is shrunk, indicating that the vacuum is still present. If the seal is

COSTERWISE LTD.16, Rabbit Row

London W8Tel: 81-2210668

SHOWSCONTAINERWAS TIPPED

OR MISHANDLED

BLUEBEADSINARROWHEAD

UPTIP-N-TELL

TIP-N-TELL

DROP-N-TELL


broken, check for signs of moisture inside the module. Make a note of any defects in the Installation Report.

6. Carefully cut away the vacuum seal wrapping and remove any bubble-wrap.

7. Remove the front block of the wooden frame to the palette, see Figure 3.2 on Page 3-4, before lifting the unit.

Figure 3.2 Unpacking FFEI module boxes

FORK STOPBLOCK

PLAN VIEW

FOAMINSERT

FORK

FRONT

REMOVEABLEFRONT BLOCK

FOAMINSERT

FORK

BEARINGBLOCKS

FORK STOPBLOCK


8. Remove any foam inserts around the palette.

9. Use the fork-lift truck to remove the module from the palette, see also Section “Using a Fork-Lift” on page 3-7. A limit block at the rear of the plinth locates the position of each fork before the unit is raised.

CAUTION: Check that the anchor feet are fully retracted.

10. Once the module is removed from its palette, carefully push or lift it to its working location.

If you need to use a harness and slings for raising the module, refer to FFEI Customer Support (UK).

11. Locate the Accessories packs and check that the items in Table 3.1 on page 3-5 are shipped.

12. Arrange locally for the removal of disposable packaging mate-rials. The box cardboard and foam are all recyclable materials.

Table 3.1 V-6 and V-6e accessories packs1 FireWire cable (10 m)

2 User’s Safety Guide

3 Getting Started Guide

4 Manifold blanking plate and (4-off M6 screws)

5 Luxel V-6 CTP (Application) CD

6 Luxel V-6 CTP (PCI) CD

7 Celebrant Luxel patch CD (requires software dongle key), if required.

8 Diagnostics comms cable (10 m or optional 25 m)

9 Vacuum pump (VT4.25)

10 Output buffer to processor (10-off M6 screws) (Semi-auto only)

11 Vacuum Nylon tube 16 mm black

12 G10 film sheet for PC next to a manual loading machine

13 Luxel CTP Product Manuals CD


NOTE: the vacuum pump and PAT are supplied as part of a sep-arate country pack, depending on what needs to be installed for the local voltage range.

3.1.4 Unpacking the Processor

CAUTION: Four people will be required to lift the processor and one to remove the palette.

Use the supplied Installation Manual to unpack the processor.

3.2 Handling the Equipment

CAUTION: Modules are very sensitive to stresses, particularly when lifting into position during an installation. Any pressure on the front or rear, or any torsional stress created by lifting a unit from the wrong points, can alter mechanical alignments. This in turn will affect registration and repeatability.

Castors are fitted to allow modules to be moved short distances

14 Mains cable

15 Top height gauge/memory plate (Autoloader only)

16 Over-ride key (Autoloader only)

17 Feet seating plates (Autoloader only)

Table 3.2 V-6 multi-cassette support pack1 Adaptor top

2 8-off M5 x 20 cap head screws

3 V6AF_CAN_AUTO cable

4 V6AF_EARTH cable

5 V6AF_MAINS_FEED cable

Table 3.1 V-6 and V-6e accessories packs (Continued)


and for manoeuvring it into its working position.

Check that the floor of the intended route is suitable and avoids jolts, bumps and vibration.

CAUTION: Ensure the operating area is clean and free from dust before moving a module into its working area. The maximum dust specification is in the Luxel V-6 Series CTP Pre-Installation Guide.

3.2.1 Using a Fork-Lift

CAUTION: Modules can easily topple over when carried on a fork-lift. Make sure they are secured and the forks are inserted in their correct positions shown on the front LIFT HERE labels.

A fork-lift truck is recommended for lifting and transporting the modules whenever possible. It must possess undistorted forks that can lift the weight of the module evenly. They should be at least 1100 mm (43 in) long and have a distance apart of between 600 mm (24 in) to 1000 mm (39 in).

1. Using a sharp knife, carefully cut away the vacuum seal wrap-ping foil close to the base of the front of the module to allow access by a fork-lift truck.

CAUTION: Ensure the forks of the fork-lift truck are dry to reduce the risk of the module sliding.

2. Taking care not to damage the castors, position the forks cen-trally under the front where the fork-lift labels `LIFT HERE' is attached, and ensure that the forks only just protrude out the other side of the module. Otherwise, you may have problems withdrawing the forks when the unit is lowered.

3. Lift the module clear of the pallet and transport it as close to the intended destination as possible.


INSTALLING LUXEL EQUIPMENTAND SOFTWARE

4.1 Start the Installation

NOTE: Information in this section applies to both the Luxel V-6 and V-6e.

4.1.1 Special Tools RequiredAs well as the basic service toolset, you will need additional tools

This chapter shows how to install and connect the Luxel V-6 and V-6e platesetter equipment for a manual and semi-automatic system.

4.1 Start the Installation ............................................................................. 4-14.2 Install the Processor ............................................................................ 4-94.3 Install the Engine................................................................................ 4-104.4 Install the Autoloader (Luxel V-6) ..................................................... 4-174.5 Install the Multi-Cassette Autofeeder (MAL) .................................... 4-284.6 Set up the System .............................................................................. 4-484.7 Install Luxel Desktop Applications and Device Driver.................... 4-584.8 Installing Licence Options and Upgrades........................................ 4-59

4-2 INSTALLING LUXEL EQUIPMENT AND SOFTWARE

for installing the system:

socket set up to 12 mm (Metric)

600 mm spirit level

adjustable spanner up to 30 mm jaw space.

4.1.2 Pre-Install ChecksBefore installing the platesetter make sure the pre-install checks in the Pre-Installation Guide have been completed. If there are any queries, consult FFEI UK Customer Services.

The PC Interface (PCI) software is installed on a RIP PC that must have the minimum system requirements given in the V-6 PCI Installation Notes supplied with the software CD media. See also Section 4.7.1 on Page 4-58.

NOTE: Check that the proposed platesetter location has a safety isolating switch readily accessible to the engine. The switch must be marked `ON' and `OFF'.

4.1.2.1 Check Floor GradientWhile the machine is not yet in position, you may need to check that the rise/fall floor gradient for the platesetter area is within the values shown in Figure 4.1 on Page 4-3 below. Use this method if the floor level appears uneven:

1. Find the proposed working location of the platesetter modules.

2. Check that the rise or fall of the floor gradient is within the specification.

3. Use the following check if the floor appears outside the specification:

A) Obtain a spirit level approximately 610 mm (24 in) long and two blocks of wood of equal size approximately 60 mm (21 in) x 60 mm.

B) Place the blocks apart at one corner of a marked machine floor area and measure the difference in height to obtain a level reading.

C) Move one block along the floor area in the X1, X2 or Y direction and measure the difference again.


D) Continue these measurements for the same direction.

E) Repeat steps B) and C) for the other two directions.

F) Total the readings for each direction separately.

G) If the gradient total is less than 30 mm (1.18 in) for all three directions then proceed with the installation.

Figure 4.1 Checking floor gradients: Luxel V-6

4. If the platesetter floor level is uneven then check for a more suitable area nearby.

5. If the floor level gradient is within specification, then start the installation using the recommended sequence. This sequence is based on a very precise engine horizontal (traverse) travel level difference of less than 0.5 mm between the two ends.

4.1.3 Remove the Module Covers

NOTE: This section applies to both the Luxel V-6e and V-6.

(X1)

(X2)

(Y)

FLOOR GRADIENT RISE/FALL REQUIREMENT:(X1) AND (X2) = LESS THAN 30 mm

(Y) = LESS THAN 30 mm


See Figure 4.2 on Page 4-4. and Figure 4.3 on Page 4-5.

Figure 4.2 Removing covers and doors: Luxel V-6e and V-6

Covers and doors should be completely removed from modules during the installation in order to access assemblies. Where possi-ble, refit them to protect the interior from dust contamination. Note the following:

SL

NL

I

SL

SL

I

SL

I

a) V-6 FULLY-AUTOMATIC (MULTI_CASSETTE)

b) V-6 MANUAL AND SEMI-AUTOMATIC

SL

NL

I

KEY:

SCREW LOCKED

NOT LOCKED

INTERLOCKED

SL

c) V-6e MANUAL AND SEMI-AUTOMATIC

SL

SL

I

SL

SL

I


Screw-locked (SL) doors are fixed into position using posidrive screws located underneath the door.

Interlocked (I) covers include a sensor to detect if they are open or closed. Before powering on the system ensure that all interlocked covers are closed, or the interlocks are overridden using the keys shown in Section 2.3.3 on Page 2-19.

NOTE: The Engine doors can be detached from the frame for improved access.

4.1.3.1 Remove V-6 Engine Top CoverThe top cover on the V-6 engine is removed as follows:

1. Open the user door and remove the 2-off posi-screws shown in Figure 4.3 on Page 4-5.

2. Lift the cover towards the user side to release it from the fixing inserts on the service side.

Figure 4.3 Removing the engine top cover: Luxel V-6

4.1.3.2 Remove V-6e Engine Top Cover (Manual)The top cover on the V-6e manual engine is removed as follows:

1. Remove the 2-off posi-screws at the rear of the top cover.

TOPCOVER

USER SIDE

INSERTSSCREWFIXING

(DOOR OPEN)


2. Lift the cover towards the back of the machine to release it from below the load platen.

4.1.3.3 Remove V-6e engine Top Cover (Semi-Auto)The top cover on the V-6e semi-automatic engine, shown in Figure 4.4 on Page 4-6, is removed as follows:

1. Open the user door and remove the 1-off posi-screw. The other side is held by a pin.

2. Lift the cover towards the output to release it from below the load platen.

Figure 4.4 Remove the engine top cover: Luxel V-6e (semi-auto)

4.1.4 Heavy Lifting Operations


Two or more people are normally required for any heavy lifting procedures where you need to:

manoeuvre the modules into position

install the processor (this unit requires 4 people to lift the unit and one to remove the palette)

TOPCOVER


position the vacuum pump.

CAUTION: Obtain assistance before lifting or manoeuvring any large modules.

4.1.5 Installation Sequence


4.1.5.1 Semi-Automatic (Luxel V-6e)Install a semi-automatic system in the the following module order Figure 4.5 on Page 4-7 below:

Figure 4.5 Install sequence: Luxel V-6e semi-automatic

4.1.5.2 Semi-Automatic (Luxel V-6)Install a semi-automatic system in the the following module order Figure 4.6 on Page 4-8 below:

(1) PROCESSOR

(2) ENGINE


Figure 4.6 Install sequence: Luxel V-6 semi-automatic

4.1.5.3 Single-Cassette Fully-Automatic (Luxel V-6)One Fully-Automatic only: Install a fully-automatic system in the the module order shown in Figure 4.7 on Page 4-8.

Two or More Fully-Automatics: install the first system as shown in Figure 4.7 on Page 4-8 and then the other systems in reverse order, see Section 4.4.4 on Page 4-28.

Figure 4.7 Install sequence: Luxel V-6 fully-automatic

(1) PROCESSOR

(2) ENGINE

(3) PLATEN

(1) PROCESSOR

(2) ENGINE(3) AUTOLOADER

(4) TROLLEY &CASSETTE


4.1.5.4 Multi-Cassette Autofeeder (Luxel V-6)One single-cassette only: Install a multi-cassette system in the the following module order Figure 4.8 on Page 4-9.

Figure 4.8 Install sequence: Luxel V-6 single-cassette

4.2 Install the Processor


CAUTION: Lifting this unit is a five-man operation.

Using the supplied Installation Manual, install the processor and its chiller unit.

1. Locate the processor in its correct working position.

2. Set the processor plate entry slot height to 1,012 mm (39.84 in) to match the output of the Engine, see Figure 4.11 on Page 4-15.

3. Level the processor at each corner.

(1) PROCESSOR

(2) ENGINE

(3) AUTOLOADER

(5) TROLLEY & CASSETTE

(4) AUTOFEEDER


4.3 Install the Engine

4.3.1 Remove Engine Transit Fixings


The Engine is shipped with a set of transit fixings that MUST be removed BEFORE switching on power. Each fixing is identified by a label colour-coded orange; all screw fixings are colour-coded green.

Remove the following transit fixings:

A) Traverse carriage - see Section 4.3.1.1 on Page 4-10

B) Platen - see Section 4.3.1.2 on Page 4-12.

C) MMI console cover.

4.3.1.1 Traverse Carriage Transit FixingSee Figure 4.9 on Page 4-11.

1. Locate the packaged ball cage assembly from its transit position taped to the top of the optics assembly (after the top cover is removed).

CAUTION: The ball cage is very delicate and easily damaged. Take care when unpacking this assembly.

2. Check that the ball cage is clean and undamaged. Lay the cage on a flat surface and check that it is straight; if it is deformed then adjust it before fitting.

3. Clean the V-groove with a lint-free cloth and solvent (for example, IPA).

4. From the user side: Insert the ball cage on the V-groove and slide it under the carriage, shown in Figure 4.10 on Page 4-12, noting the orientation. Push it towards the service end until it is up against the service end stop.

If it is difficult to slide the ball cage between the V-grooves under the carriage then slacken the transit screws slightly.


Figure 4.9 Removing the traverse transit bolt

TRANSIT BRACKET SCREWFIXINGPOINTS

SCREWFIXINGPOINT

ORANGETRANSITSCREW


Figure 4.10 Fitting the ball cage

5. From the service side: from the right hand side of the carriage, support the carriage by hand and unscrew the orange transit fixing screw fully-anti-clockwise. It is not possible to remove it completely until the transit bracket on the other side has been removed and the carriage is free to move.

6. From the service side: using a M5 Allen key, loosen the 2-off screws on the traverse transit bracket (left hand side of carriage), see Figure 4.9 on Page 4-11, while supporting the traverse carriage by hand from the motor casting.

7. Remove the lower screw on the bracket and then the two top screws. Remove the bracket very carefully, making sure that cables are not damaged. Gently lower the carriage on to the traverse beam and ball cage.

CAUTION: Hold the carriage and lower carefully so as not to damage the ball cage race and encoder strip.

4.3.1.2 Platen Transit Fixings (V-6 Only)Remove the transits on the four pins (lift and centre).

CARRIAGERAIL

BALL CAGE

TRAVERSERAIL


4.3.2 Integrate the Processor and Engine


4.3.2.1 Set the Processor HeightUsing the supplied OEM Installation Manual, install the processor and its chiller unit.

See Figure 4.11 on Page 4-15.

1. Locate the processor in its correct working position.

2. Remove the processor top cover and heater cover.

3. Slide a solid 6-inch steel rule (or straight edge) between the rubber nip rollers and the plastic input rollers until it is sticking out the front guide in the centre. It should be level with the heater plate.

4. Using the appropriate 12 mm and 16 mm spanners, adjust the feet so that the bottom of the rule is 1,012 mm from the floor.

Make sure the input rollers and tank frame are level in both planes.

NOTE: Do not use the engine panels for levelling.

5. Re-adjust the feet if necessary while maintaining the correct height at the centre.

6. Remove the rule.

4.3.2.2 Mate the Engine to the ProcessorSee Figure 4.11 on Page 4-15.

1. Fit the processor input plate (buffer) with the screws supplied in the Accessory Pack.

2. Position the engine frame against the processor buffer frame.

3. Adjust the engine feet until both frames are roughly at the same height.

4. Level the engine drum/beam/optics cover assemblies in both planes using a spirit level. See Figure 4.13 on Page 4-17.


5. Place the steel rule against the top surface of the output guide and slide the guide into the processor and over the small plastic input rollers.

6. Adjust the engine height until the underside of the steel rule is approximately 2 mm above the lower input roller. Check from each end.

If the floor is outside the recommended minimum specification, set the anchor feet to their lowest setting and re-adjust the processor. Adjust the appropriate corners upwards to obtain improved levelling using 12 mm and 16 mm spanners. See Figure 4.12 on Page 4-16.

See Section 4.3.3 on Page 4-15 for more information on levelling the engine.

7. Check the drum assembly is still level in both planes and re-adjust if necessary.

NOTE: Do not use the engine panels for levelling.

8. Refit the processor covers.

9. Connect the comms cable from the processor to the engine.

10.Connect the processor power cables.


Figure 4.11 Levelling the engine and processor

4.3.3 Level the Engine


4.3.3.1 Manual System See Figure 4.12 on Page 4-16.

1. Locate the engine in its working position.

2. Set the height as shown in Figure 4.11 on Page 4-15.

RULERPLASTIC INPUT

ROLLERS

RUBBER NIPROLLERS

2 mm

1012 mm

OUTPUTGUIDE HEATER

PLATE

ENGINE PROCESSOR


Figure 4.12 Adjusting the engine castors and feet

4.3.3.2 All Variants 1. Service to User direction: place a 600 mm spirit level on the

traverse motor drive rail, avoiding the encoder scale, see Figure 4.13 on Page 4-17.

ANCHORFOOT

CASTOR 12 mm

16 mm


Ensure that the horizontal level between the two ends is less than 0.5 mm.

2. Input to Output direction: using a 600 mm spirit level, check along the top of the engine skin.

3. Make sure the full weight of the machine is evenly on all four anchor feet and there is no movement at any corner.

If the engine is installed on a floor with a soft surface (rubber tiles, for instance), check the level again after 24 hours for any signs of anchor feet sinking.

4. Replace any covers.

Figure 4.13 Vertical levelling

4.4 Install the Autoloader (Luxel V-6)

NOTE: Information in this section only applies to the Luxel V-6.

This section explains how to install an autoloader with and with-out a Manual loading Slot (MLS).

4.4.1 Remove Autoloader Transit FixingsThere are four transit fixings: two each side of the nudger lift and two each side of the diverter assembly (see Figure 4.14 on Page 4-18 and Figure 4.15 on Page 4-19).

ENCODERSCALE

TRAVERSEDRIVE RAIL

600 mmSPIRIT LEVEL


Figure 4.14 Remove the diverter transit fixings

1. Remove the top interlocked cover from the autoloader.

2. Remove the nudger lift and diverter transit fixings (2-off M4).

3. Remove the cassette lid and lift out the two polystyrene blocks.

4. Remove the tape holding down the cassette lid flap.

5. Remove the polysterene block holding the autoloader cassette input door in position.

DIVERTERTRANSIT FIXING

(RIGHT)

DIVERTERTRANSIT FIXING

(LEFT)


Figure 4.15 Remove the nudger transit fixings

4.4.1.1 Remove the MLS Transit FixingsRemove the following (see Figure 4.16 on Page 4-20):

A) Tape holding the door closed.

B) Transit screw on the M-roller assembly.

NUDGER LIFTTRANSIT FIXING

(RIGHT)

NUDGER LIFTTRANSIT FIXING

(LEFT)


Figure 4.16 MLS transit screw

TRANSITSCREW

M-ROLLERASSEMBLY

MLS COVER

TAPE(BOTH ENDS)

NUDGERFRAME

NUDGERTRANSITFIXING

NUDGERARM


4.4.2 Mate the Autoloader and EngineThe autoloader and engine are mated as follows:

1. Move the autoloader close to the engine and route the following cables between the two units:

1. V6A_ILOCK: from the autoloader interlock switch to the free end of V6_ILOCK (after detaching the shorting connector - if fitted).

WARNING: make sure this cable is fitted to ensure full operator safety when the auoloader top cover is removed.

2. V6A_CAN_AUTO: from MSB3 SK1 to MSB2 SK3. This cable is in the Accessories pack.

3. V6A_MSB3_PWR: from MSB3 PL31 to MSB3_PWR connector on the Interlock box. Route this cable back to the Interlock box on the engine and secure.

4. Check that LK1 and 2 are not fitted on MSB2 and fitted on MSB3, see Figure 4.17 on Page 4-21.

Figure 4.17 Location of LK1 and 2 on MSB2

2. Obtain the 4-off seating plates (anchor feet) from the accessories pack and locate them underneath each autoloader jack bolt, see Figure 4.18 on Page 4-22.

LK1

LK2


3. Mate the autoloader to the engine adaptor assembly as follows:

A) Locate the two adaptor plate pins inside the two autoloader keyholes.

B) Raise the autoloader feet gradually (using a 8 mm spanner) so that the two adaptor assembly pins are touching the bottom lip of the keyhole slot, see Figure 4.19 on Page 4-23.

4. Check that the autoloader is level using a spirit level on the top frame cover.

5. Lock the four autoloader feet.

6. Using the previously removed 5-0ff M5 screws, fix the autoloader to the adaptor assembly, see Figure 4.19 on Page 4-23.

Figure 4.18 Adjust the autoloader feet

8 mm

LOCKINGNUT

JACKBOLT

SEATINGPLATE


Figure 4.19 Locate the adaptor pins and keyhole slots

M5 SCREW(5-OFF)

ADAPTORASSEMBLY

(FITTED TO ENGINE)

AUTOLOADER

ADAPTORPLATE PIN

(2-OFF)

KEYHOLE(2-OFF) AUTOLOADER

ADAPTORASSEMBLY

KEYHOLE

PIN IN SLOTCONTACTING

LOWER LIP


4.4.3 Level the Trolley and Cassette

NOTE: It is very important that the cassette lid is closed cor-rectly after loading plates, and that both latches are holding the lid in place. Failure to do this will result in plate loading or paper handling errors.

1. Prepare the autoloader and cassette as follows:

A) Remove the cassette lid.

B) Remove the two side bumpers from the cassette platen (3-off M4 screws).

C) Tape the cassette input door to the top cover so that it is held open.

D) Temporally remove the service side autoloader door and open the paper bin door.

E) Remove the protect cover on the users side (2-off, M4 screws) so that there is a clear side view of both cassette locating pins on the autoloader. See Figure 4.20 on Page 4-25.

CAUTION: At this stage, make sure you push the trolley into the autoloader very carefully to avoid damaging autoloader compo-nents.

2. Carefully push the trolley into the autoloader bay and check from each side if the two cassette locating pins line up with their two holes on the cassette interface, see Figure 4.21 on Page 4-26.

3. Adjust the trolley height as follows (see Figure 4.22 on Page 4-27):

A) Using an adjustable spanner (up to 30 mm jaw span), loosen the four locknuts on the castors.

B) Adjust the castor wheel height by turning the wheel hood (clockwise to raise).

C) Put a 600 mm spirit level lengthways on the platen and keep adjusting the height and level of all four wheels until the locating pins are lined up with the cassette holes, see Figure 4.22 on Page 4-27.


D) If the adjustment length on the bolt is not enough (trolley needs to go higher), then remove the castor and refit with the locknuts below the pads.

4. Pull out the cassette and tighten all four castor locknuts.

5. Push the cassette back into the bay and make sure that the locating pins locate smoothly into the cassette, and you can hear the cassette latch ‘snap’ to engage correctly. Check that the latch is hooked around the pin, see Figure 4.21 on Page 4-26.

6. If the cassette fails to latch then re-adjust the trolley height.

7. Refit the autoloader doors.

8. Refit the protect cover and the service side door.

9. Refit the cassette lid, bumpers and release the input door flap.

Figure 4.20 Remove the protect cover

PROTECTCOVER

ADAPTOR ASSEMBLY


Figure 4.21 Autoloader locating pins

LOC

ATIN

GP

INLA

TCH

BU

MP

ER

LOC

ATIN

GP

INH

OLE

LATC

HP

INLA

TCH

HO

OK

ED

AR

OU

ND

PIN

LATC

HP

INLA

TCH

HO

OK

ED

AR

OU

ND

PIN

VIE

W1

VIE

W2


Figure 4.22 Adjust the trolley height

LOCKNUT

LOCKNUT(BELOW PAD POSITION)

PAD

WHEEL HOOD(CLOCKWISE TO RAISE)

WHEEL

TROLLEY

CASTOR WHEEL(4-OFF)

TROLLEYBASE

1

2

CHECK LEVELS1 AND 2


4.4.4 Set the Second Trolley HeightIf the installation has two or more autoloaders then the height adjustment for each machine should allow the transfer of trolleys between autoloaders.

To set the trolley heights follow the procedure set out below.

1. Install the first machine as normal in this order:

1. Processor

2. Engine

3. Autoloader

4. Cassette and Trolley.

2. Adjust the second cassette height to match the installed autoloader height. The second cassette can now be used as a guide for installing the second autoloader. Starting with the second cassette install the second machine as follows.

1. Cassette and Trolley

2. Autoloader

3. Engine

4. Processor.

3. If you follow this procedure correctly you will have two correctly installed autoloaders with matching trolley and cassette heights.

4.5 Install the Multi-Cassette Autofeeder (MAL)

CAUTION: Do NOT manually move cassettes from the Autoloader into the Autofeeder. If a cassette has been moved forward by hand to check alignments then it must be pushed back before the machine is switched on.

Follow all the Installation steps in the sections above for installing a processor, engine and autoloader. Note the following:

Before installing an Autoloader, thread the 4-off cables listed in Section 4.5.2 on Page 4-33 through the autoloader cable holes at the top input location.

Do not remove the MLS transit bolt.


Connect the Diagnostic cable between the RIP PC or laptop and MSB 4 (PL16), see Figure 4.27 on Page 4-35.

If you need to manually raise or lower the shelves then use the procedure in Section 4.5.3 on Page 4-37 or the Cassette Change procedure

4.5.1 Integrate and Level the Autofeeder (Basic Level)

NOTE: A basic levelling of the two units is made before the two units are correctly aligned for smooth cassette transfers. A fine level check is made at the end of the alignment.

1. Before installing an Autofeeder, route the 4-off cables listed in Section 4.5.2 on Page 4-33 through the autoloader interconnect cable holes.

2. An adaptor top is already fitted to the autoloader, see Figure 4.23 on Page 4-30.

Tighten the two lower screws on the adaptor top so that the adaptor extensions are tight against their support ledges, see Figure 4.25 on Page 4-33.


Figure 4.23 Locating the top adaptor plate

3. Locate the autofeeder in its working position next to the autoloader and adjust the four jacking feet to get the two modules approximately level.

4. From the service end first, lift off the wooden transit block securing the elevator to the frame.

CAUTION: Do not lift off the user end first.

NOTE: The wooden transit block under the elevator is removed at a later stage after elevator is manually raised.

5. Position a 600 mm or more spirit level along the autofeeder shelves to check levels in X and Y directions and adjust the level, see Figure 4.24 on Page 4-32.

6. Push the autofeeder frame up to the adaptor top so that:

the left and right hand support ledges align on the inside face, and

AUTOLOADER

SCREW FIXINGHOLES

ADAPTORASSEMBLY


the angle plates slide inside the rear part of the autofeeder.

7. Adjust the level of the autofeeder so the adaptor plate extensions are level with the two opposing cassette support ledges. Slide a small metal rule along the two surfaces and check that it moves smoothly across in both directions, see Figure 4.25 on Page 4-33.

8. Continue to interconnect the cable and load the software before checking the mechanical alignment of the autofeeder and autoloader, see Section 4 on Page 4-43.


Figure 4.24 Levelling the autofeeder

CASSETTE/TROLLEY

CASSETTE/TROLLEY

AUTOLOADER/ENGINE

AUTOLOADER/ENGINE

AUTOFEEDER

AUTOFEEDER


Figure 4.25 Ledges and extensions are level

4.5.2 Connect the Autofeeder CablesAttach the following cables betwwen the autoloader and the autofeeder:

V6AF_Mains_Feed (99700688): this is routed to avoid signal cables. Fit the IEC connector at the rear of the Interlock box (ILOCK) and run along the base of the engine. Make sure the cable is passed through the lower autofeeder hole and con-nected to the elevator motor control assembly, see Figure 4.26 on Page 4-34.

AUTOFEEDERAUTOLOADER

ADAPTOREXTENSION

SUPPORTLEDGE

METALRULE

SUPPORT PADS


Figure 4.26 Interlock box to mains connection

MSB_Power (99700690): connect the free end from the Inter-lock box ILOCK MSB3 connector to MSB 4 (PL31). Route the cable through the top access hole in the autofeeder.

MAINS OUTPUTTO AUTOFEEDER


Figure 4.27 MSB 4 connectors

PL8 PL10

PL25PL24PL23PL7 PL9 PL12 PL14 PL21

PL26

PL18

PL19

SK3

SK2

PL6

PL5

SK1

PL4

PL3

PL2

PL1

PL15 PL16 PL20 PL22

PL31

PL17

PL27

PL28

PL29

PL30

PL11

PL13

LK1

LK2

PL33

TP3 CAN 5V

TP1 GND


Figure 4.28 Fit the earth wire

V6AF_Earth (99700684): this cable is attached between the earth fixing points on the autoloader and autofeeder, see Figure 4.28 on Page 4-36. Route the cable through the bottom access hole on the autofeeder.

WARNING: an earth wire MUST be fitted between the autoloader and autofeeder.

Check for earth continuity between the two modules.

WARNING: Make sure the cable safety labels are attached as shown in Chapter 2.

CAN_Auto Cable (99700679) fit this cable between MSB 3 (SK3) and MSB 4 (SK1). Route the cable through the top access hole on the autofeeder.

AUTOLOADER

EARTH WIREFROM AUTOFEEDER


Figure 4.29 Routing of autofeeder cables

4.5.3 Remove Transit Fixings Using the Brake Override

WARNING: Keep away from moving parts on or near the scissor-jack elevator while using this procedure. Safety features on the autofeeder are overridden.

Use the brake override procedure below to manually raise and lower the scissor-jack mechanism for access to the transits.

Item Required: brake override switch assembly (7A10980). This assembly routes +24 VDC directly to the two safety solenoids and the brake relay to release the solenoids and the motor brake.

UPPERHOLE

LOWERHOLE

EARTHWIRE

POWER

TO MSB4


4.5.3.1 Set up the Brake Override1. Switch off the engine (if it is already on).

2. Connect the brake override switch as follows (see Figure 4.30 on Page 4-39):

A) Disconnect the power cable (PL31) from MSB4 and connect it to the long cable extension of the brake override.

B) Disconnect the inline connector between MSB_DOOR CABLE (99700704) and DOOR_LOCK (99700683) and connect the door_lock end to the short cable extension of the brake override.

3. Switch on the engine and put into Boot mode by pressing [Ctrl-c] when requested. This will suppress any error messages.

4. Remove the two elevator side transits after tensioning the chain and raising the elevator, see Section 4.5.4 on Page 4-40 and Section 4.5.3.2 on Page 4-40.

5. Remove the three cassette transits shown in Section 4.5.4 on Page 4-40.

If necessary, use one of the procedures below to lower (Section 4.5.3.2 on Page 4-40) or raise (Section 4.5.3.3 on Page 4-40) the elevator for accessing the cassette transits.


Figure 4.30 Connecting the brake over-ride assembly

MSB4

INVERTER

PL31

PL1/PL2

MSB_PWR

MSB_DOOR

DOOR_LOCK

BRAKEOVERRIDEASSEMBLY

SWITCH

A

B

A

B

MSB_PWR CONNECT TO

CONNECT TO


4.5.3.2 Lower the Elevator1. Depress the override switch and turn the elevator motor spindle

anti-clockwise to tension the chain.

2. Depress the switch briefly in short steps to release the brake and allow the shelves to lower under their own weight.

CAUTION: Make sure the elevator does not accelerate too quickly.

3. If the elevator fails to drop then keep the switch depressed and turn the motor shaft to reach the required position.

4.5.3.3 Raise the Elevator

WARNING: If the shaft spins out of control then release the switch. Do not attempt to hold the shaft.

1. Use a tool or turn the motor shaft by hand to move the shelves up (anti-clockwise) or down (clockwise).

2. Depress the override switch to release the brake.

3. Turn the elevator motor shaft anti-clockwise to tension the chain.

4.5.3.4 Remove the Brake Override1. Once the transits have been removed, switch off the engine.

2. Disconnect the brake override assembly and:

A) reconnect PWR to MSB4 and

B) reconnect MSB_DOOR and DOOR_LOCK cables.

3. Switch on the engine and load the LuxelDesktop application (see Section 4.7 on Page 4-58) to allow you to remove the remaining transit fixings on the cassette and elevator.

4.5.4 Remove the Transit FixingsRemove the transit fixings on the autofeeder shown in Figure 4.31 on Page 4-41 and Figure 4.32 on Page 4-42.

A) Cassette corner: remove the cassette corner brackets(2-off screws) on each of the cassettes.


B) Elevator side: remove the 2-off elevator side brackets (4-off screws) on each side.

C) Cassette rear: remove the 1-off (2 screws) cassette rear bracket during the Cassette Change procedure.

Figure 4.31 Removing transit fixing (view 1)

ELEVATOR SIDE TRANSIT

CASSETTE CORNERTRANSIT


Figure 4.32 Removing transit fixing (view 2)


4. With the system switched on and the LuxelDesktop application loaded, use the Change Cassette procedure (see the Luxel V-6 PCI User’s Guide) to open the cassette door.

CAUTION: Do not select the TOP shelf during a Change Cassette before removing the wooden transit block at the front of the ele-vator.

5. Start a Change Cassette procedure for the middle shelf cassette (2), open the cassette door and remove the cassette rear transit fixing.

6. Remove the wooden block under the front of the elevator by lifting up and pulling out from the user side.

7. Select the bottom cassette for a Change Cassette and remove the transit fixings.

4.5.5 Integrate and Level the Autofeeder (Fine)

CAUTION: ALWAYS push the cassette back into the Autofeeder before switching ON the system.

NOTE: make sure all the transit fixings are removed before start-ing the fine alignment.

In this procedure the two modules are aligned more accurately so that cassettes move reliably to the correct mount position on the autoloader.

1. Viewing from the top of the autofeeder, manually push the cassette towards the autoloader. It should latch and ‘click’ into the mount position.

2. If the cassette fails to mount properly then check the cassette alignment to ensure:

A) there are evenly matched spaces beween the cassette and the adaptor panel on each side, see Figure 4.33 on Page 4-44,


Figure 4.33 Checking autofeeder-autoloader alignment

3. Push the cassette into the two location pins and note if the cassette front end has to ‘nudge’ in either horizontal direction to reach the correct mount position.

CAUTION: ALWAYS push the cassette back into the Autofeeder before switching ON the system.

CASSETTE

ADAPTORSIDE

AUTOFEEDER

AUTOLOADER

ADAPTORSIDE

CAUTION

CAUTION:MAKE SURE CASSETTEIS PUSHED BACK INTOAUTOFEEDER AFTERTHIS CHECK


NOTE: Unlatch the cassette from the autoloader by pulling back the latch arm under the cassette base.

4. If there is slight movement then:

raise the autofeeder feet

move the autofeeder slightly in the same ‘nudge’ direction to re-align with the location pins

lower the feet on the autofeeder.

5. Repeat the steps above to check the alignment again until the cassette latches correctly.

6. Tighten the 4-off screws on adaptor angles and the 4-off screws on the adaptor top.

7. Check the level between the two units, see Figure 4.25 on Page 4-33.

8. Once the two modules are level, secure the two units together with 4-off M5 x 20 cap head screws supplied in the Support Pack, see Figure 4.34 on Page 4-46.


Figure 4.34 Securing the autofeeder and autoloader

4.5.6 Levelling the Trolley1. Use Cassette Change to remove a cassette on to the trolley.

2. Load the cassette with plates.

3. Adjust the trolley feet so that the side bumpers are level with the guides shown in Figure 4.35 on Page 4-47.

4. Dock the trolley, check that the docking light is on and push the cassette forward until it latches.

NOTE: Unlatch the cassette from the autoloader by pulling back the latch arm under the cassette base.

5. Repeat the procedure for the other shelves.

6. Two man lift: fit the top autofeeder pod and secure into position at each corner (4-off screws in support pack).

M5 x 20 CAP HEADS


7. Refit all the covers.

Figure 4.35 Levelling the trolley

BUMPER GUIDE

CASSETTE BUMPER

CASSETTE BUMPER

BUMPER GUIDE


4.6 Set up the System

NOTE: Information in this section applies to both the Luxel V-6e and V-6.

4.6.1 Align Carriage and Ball CageBoth the traverse carriage and ball cage are setup manually so that they always move back and forward as aligned assemblies. The procedure below is carried out at the user end of the Engine.

1. Hold the ball cage and push the carriage back until a length of the cage is exposed.

2. Pull the carriage forward, holding the ball cage as required until the two assemblies are inline with the screw fixing as shown in Figure 4.36 on Page 4-48 below.

3. You may have to repeat steps 1. and 2. several times to align the ball cage and carriage accurately.

4. The alignment and level is checked at a later stage using a cage creep utility described in Section 5.2.4 on Page 5-5.

Figure 4.36 Carriage rail and ball cage alignment

ALIGN BALL CAGE ANDCARRIAGE RAIL HERE

CARRIAGERAIL

BALLCAGE

USERENDVIEW

FIRSTSCREW

V-GROOVE


4.6.2 Connect Power and EquipmentSee Figure 4.37 on Page 4-49 below.

1. Connect the following cables from the rear of the Engine to the mains outlet and linked equipment:

A) EXTERNAL ALERT (to a remote light or buzzer supplied and fitted by the customer as an option).

Cables B), C) and D) listed below are fitted through the light-seal entry and connected directly to the Formatter Board, see Figure 4.37 on Page 4-49 and Figure 4.38 on Page 4-50.

Figure 4.37 Engine equipment connections

MAINS ON/OFFSWITCH

VACUUMOUTLET

SERVICE SIDE

MAINSINLET

RATINGLABEL

ENGINE

CONTACTORFAULT LED

AUTOLOADERCOVER LED

USER DOOR LED

EXTERNALALERT

OUTLET

VAC PIPE INLET/FIREWIRE/ RS232/PROCESSOR COMMS

LIGHT-SEAL ENTRY (INSIDE)


B) FIREWIRE (to the RIP/GUI PC). This may include hub repeaters if the distance between the two units is greater than 4,500 mm. Either Firewire port on the Formatter Board can be used.

C) RS232 DIAGNOSTICS RS232 to the RIP/GUI PC, if required. Alternatively, connect to a local laptop for installation use.

D) RS232 Processor Comms cable to the Processor (semi- and fully-automatic only).

E) MAINS_IN (to the local mains outlet and circuit breaker). Check that a wall-mounted mains isolator has been fitted that is readily available to the operator.

Figure 4.38 Formatter cable connections

INTERLOCK

RS232 (PROCESSOR)

RS232 (DIAGNOSTICS)

DATA_LCB

MMI (STATUS PANEL)

MMI (LCD)

CAN_LCB

CAN_STB

SPARE (CAN)

FAN

POWER (I/L)

FIREWIRE

FORMATTERPCB


4.6.3 Attach the PAT Air Filtering SystemSee Figure 4.39 on Page 4-51 below.

The PAT Air Filter (506id) reduces dust contamination inside the drum and optics module by generating clean filtered air. Use the supplied manufacturer’s Installation and Operator’s Guide to obtain details on how to register the unit before it is switched on. Without registration and a supplied access code the system will not start.

Figure 4.39 Fitting the PAT air filter

SERVICE ENDDOOR

PAT MANIFOLD


1. Unpack the PAT unit and move it to the recommended location of for the type of platesetter to ensure purity of air supply.

Fully-automatic: next to the autoloader service door

Manual and Semi-Automatic: between the platen and the engine service door.

See the Luxel V-6 Series CTP Pre-Installation Guide.

2. Fit the PAT manifold to the Engine service side door, see Figure 4.39 on Page 4-51. The manifold and fixings are shipped with the PAT unit.

3. Fit the appropriate mains outlet connector to the supplied power cable, plug in the PAT unit and switch on.

4. Check the following LEDs:

Power is ON

1, 2 and 3 Filters are OFF

Low flow is OFF.

5. Move the unit to be next to the Engine.

6. Attach the flexible duct to the PAT and run the PAT for 15 minutes to expel any dust.

7. Using the supplied Jubilee clips, attach the duct between the unit output and the manifold.

4.6.4 Connect the Vacuum Pump

CAUTION: The pump is a two-man lift.

A vacuum pump is supplied with the equipment for generating drum vacuum. If there is a problem of obtaining the correct volt-age for running the pump refer to FFEI Customer Services (UK).

CAUTION: Locate the pump so that the exhaust is directed away from the engine and the PAT.

Connect the following cables:

1. Vacuum tube: Fit the tube, supplied in the accessories pack, as shown in Figure 4.40 on Page 4-53.


NOTE: Make sure all tubes are fully seated to ensure a tight seal. You can moisten the tube end with water but do NOT use an oil-based lubricant.

2. Power/control cable: connect to the power outlet at the rear of the engine, see Figure 4.37 on Page 4-49.

Figure 4.40 Fitting the vacuum tubing

4.6.5 Connect the Processor Earth CableThe two standard processors, from manufacturers G&J and Heights (Inca), used on this product require an earth braid to be fitted from the processor to the engine to avoid power spikes.

4.6.5.1 G&J Earth Cable Fitting

From the engine end: 1. Switch off the engine and isolate from mains supply.

2. Obtain the V6_Processor_Earth (99700651) from the support pack and pass one end through the cable entry slot, see Figure 4.41 on Page 4-54 (a).

3. Fit one end of the cable to the base earth stud.

From the processor end: 4. Switch off the engine and isolate from mains supply.

5. Remove the processor side cover to gain access to the mains electrical box.

6. Feed the cable end, marked ‘G&J’ through the cable entry hole at the back of the box.

LIGHT-SEALENTRY

VAC TUBE

TO VACPUMP

VALVE CAGE


7. Fit the cable to the earth stud shown in Figure 4.41 on Page 4-54 (b).

8. Replace the processor cover.

Figure 4.41 Fitting the processor earth to the engine

BASEEARTH

STUD

CABLEENTRYSLOT

BASEEARTH

STUD

EARTHSTUD

CABLEENTRY

b) G & J PROCESSOR

c) HEIGHTS INCA PROCESSOR

a) V-6 ENGINE


4.6.5.2 Heights (Inca) Earth Cable Fitting

From the engine end: 1. Switch off the engine and isolate from mains supply.

2. Obtain the V6_Processor_Earth (99700651) from the support pack and pass one end through the cable entry slot (see Figure 4.41 on Page 4-54 (a).

3. Fit one end of the cable to the base earth stud.

From the processor end: 4. Route the cable to the processor earth stud shown in Figure 4.41

on Page 4-54 (c).

4.6.6 Fitting the PC G10 Film FilterIf the RIP PC is located close to a manual or semi-automatic engine, then there is a risk that the monitor light can cause plate fogging. Assess the risk with the customer and fit the supplied encapsulite G10 yellow film as follows:

1. Cut out the film sheet so that it fits the monitor screen.

2. Tape the film to the monitor from all four sides.

4.6.7 Final Visual ChecksAs a final check make sure that:

All the module interface cables are connected.

All the cables to ancillary equipment are connected.

All transit fixings are accounted for.

The correct circuit breaker (type and rating) is fitted for the platesetter room mains distribution to the machine (see the ratings label at the rear of the Engine).

4.6.7.1 Plate Output Alignment ChecksTo make sure plates are not skewed and jammed at the output module as a result of engine transit, carry out the following checks:

No Punch machines: check that the alignment holes on the out-put plate and the drum output guide are aligned within 1 mm,


see Figure 4.42 on Page 4-56.

Figure 4.42 No Punch output alignment

Punch machines: check that the punch output platen is flush with the punch exit slot, see Figure 4.43 on Page 4-57.

TRANSPORTGUIDE

OUTPUT GUIDE

TRANSPORTGUIDE

OUTPUTGUIDE

A

TRANSPORT GUIDE HOLEAND OUTPUT GUIDE HOLE

ARE ALIGNED

VIEW ON ARROW A


Figure 4.43 Punch output alignment

4.6.8 Clean Engine Drum1. If the engine doors have been opened for a lengthy period then

vacuum the drum or clean it with a lintless cloth to remove dust.

2. Close all covers to prevent any more dust from entering the engine.

3. Switch on the PAT.

PUNCH OUTPUT

PUNCH

PLATEN

4 mm

EXITSLOT

PLATEN

PUNCH


4.7 Install Luxel Desktop Applications and Device Driver

The engine firmware is factory-installed from a set of CDs sup-plied with the system.

NOTE: Information in this section applies to all the Luxel V-6 and V-6e variants.

NOTE: The LuxelServer Installation Guide and Release Notes, shipped on the LuxelServer software media, provide the latest information on how to install the software. Always refer to this information before starting the installation.

Two software bundles as two CDs are installed at this stage:

LuxelServer: includes the device driver.

Luxel Desktop: includes the V6 and V-6e dashboard.

4.7.1 System Pre-Requirements1. The PC operating system must be one of the following for

running the LuxelServer and Dashboard:

Windows 2000 NT Server (with Service Pack 4), or

Windows 2003 Server, or

Windows XP Pro (with Service Pack 1).

2. In addition, the PC must have installed free of charge:

Acrobat Reader (minimum level V6.0).

Microsoft Internet Explorer (minimum level V6.03).

Microsoft (Hilgraeve) Hyperterminal (minimum level V6.3).


4.7.2 Installing the LuxelServer

NOTE: Remove any previous installations of the LuxelServer before the installation.

The LuxelServer application must be running before the engine and PCI functions correctly.

The software on the supplied Luxel V6 CTP Disk 1 CD is loaded using an InstallShield Wizard.

Note the following:

1. Install the PCI software before the RIP software.

2. A typical site installation on a PC assumes that the PCI applica-tion has not been previously loaded. If a version of the soft-ware is still loaded (and not at the correct level), remove it using the procedure in the PCI Installation Guide.

3. After loading PCI software:

A) restart the PC.

B) switch on the platesetter.

4.7.3 Install the LuxelServer (Device Drivers)Device drivers are installed automatically from the LuxelServer CD. If there any problems then consult the LuxelServer Installa-tion Notes.

4.7.4 Install the LuxelDesktopThe Dashboard software is installed automatically once the CD is inserted.

4.8 Installing Licence Options and Upgrades


NOTE: Obtain all licence keys before starting an installation.


4.8.1 Obtaining Licence KeysIMPORTANT: Completing and submitting an Installation Report ensures that FFEI (UK) will have the correct information to offer long-term support for the customer.

The product options (hardware and software) should be installed at this stage before plates are tested with customer jobs. To obtain the licence key for the ordered option(s), navigate to the FFEI SIO site (http://touchbase.ffei.co.uk) and open the online Installation Report from Installation Data.

1. Select Edit and enter:

A) Name of the customer.

B) Start date of the installation.

2. Save the Report.

3. Open the Report again to display a list of licence keys for the configuration.

NOTE: One key may include all the ordered options for an instal-lation.

4. Copy and paste a key into the Licence Manager (Maintenance) on the PCI, see Figure 4.44 on Page 4-61, and press Confirm.


Figure 4.44 Licence Manager: entering the key

5. Switch on the engine.

6. Make sure the customer is aware of their keys by supplying a text file copy.

Once the product is ready for shipping, you can obtain its licence key(s) from SIO in advance of the installation start date. Other sections on the Report can be completed and submitted at the end of the installation.

All new hardware upgrades to an existing machine are supplied with their own Installation Manual, which are downloaded from SIO. New software options will normally require the local service engineer to install the licence and check the machine output.

The procedure for obtaining licence keys for all newly ordered options on an installed machine is the same as above, except that the Distributor will also receive a Faxed Order Confirmation with the new key.

You are now ready to start the commissioning checks on the platesetter described in Chapter 5.

ENTER KEY

CONFIRM


COMMISSIONING THE LUXELV-6 SYSTEM

NOTE: Information in this chapter applies to both the Luxel V-6 and V-6e.

5.1 Start to Commission the PlatesetterSystem commissioning is divided into stages:

1. Initial machine and software checks and setups:

diagnostics menu and engine clock

power supply

This chapter describes how to test, set up and demonstrate a manual, fully-automatic and semi-automatic platesetter (with and without a punch) as a working unit for the customer.

5.1 Start to Commission the Platesetter................................................... 5-15.2 Initial Software Checks and Setups.................................................... 5-25.3 Setting up Optics and Imaging............................................................ 5-85.4 Checking Plate Output (without a Punch)........................................ 5-215.5 Checking Plate Output (with a Punch) ............................................. 5-25

5-2 COMMISSIONING THE LUXEL V-6 SYSTEM

interlock doors and covers

traverse level check

plate feed

processor setup.

2. Optics setups: the optics system is fully tested at the factory but needs to be configured for the installation.

3. Platesetter plate handling: plates are transported through the system and adjustments are made to handling mechanisms on each of the modules.

4. Install and commssion the RIP: install and launch the RIP soft-ware.

5. Run customer jobs and demonstrate product: the complete platesetter system is checked with job images downloaded from the RIP.

Each stage is carried out in the recommended order described in this chapter using additional information from the:

PCI and/or MMI User’s Guide (if the MMI option is fitted).

Engineer's Reference Guide.

RIP Documentation (for the appropriate application).

RIP/server/network/PC documentation.

Processor documentation.

5.2 Initial Software Checks and Setups

5.2.1 Open Main Diagnostics and Check Engine Clock

See the Luxel V-6 Series Engineer's Reference Guide.

To run all the procedures in this chapter connect a PC or laptop terminal to the RS232 Diagnostics connector on the Engine, see Figure 4.38 on Page 4-50, or use the RIP/GUI PC if there is a Diag-nostics cable connection to the Engine.

1. Switch on the platesetter.


2. Open the HyperTerminal window:

Start > Program > Luxel V-6 PCI > Diagnostics Terminal3. Set the Properties options for the platesetter comms link to the

terminal as follows:

Connect: COM1 or 2.

Settings: Autodetect.

Configuration: 9600 bits per sec; 8 data bits; No parity; 1 Stop bit; No flow control.

32-bit display.

4. If you need to transfer scrolled text to a selected file from the HyperTerminal window, switch on Capture Text from the Transfer menu and enter a filename for saving the captured text.

5. From the (Main>) prompt open the Diagnostics menu.

main>diagnosticsEnter password: *** (uk0)

6. Check the current time and date on the Engine using:

service/time/now7. If it is incorrect, then set the time and date as follows:

service/time/set_time YY MM DD d hh mm sswhere:

YY = 2 digit yearMM = monthDD = day of monthd = day of week (1 is Monday)hh = hourmm = minutess = seconds.

5.2.2 Check Power Supply VoltagesCheck the power supply voltages by running:

service/sensors/environ

All voltage readings should be within +/- 5% of the nominal volt-


ages (see the Luxel V-6 Series Engineer’s Reference Guide).

5.2.3 Check Cover InterlocksSee the Luxel V-6 Series Engineer's Reference Guide.

1. Luxel V-6 and V-6e: While the system is switched on, check the operation of the engine and autoloader interlocks. With the engine user door and autoloader top cover closed, enter:


Check that the interlock status message is “OK, all covers closed, both contactors closed”.

2. Luxel V-6: Remove the autoloader top cover.

Check the status changes to code $1e ‘INTERLOCK BROKEN: Autoloader cover open’.

Check if the following devices stop:

plate handling motors

laser light

spinner

vacuum pump.

3. Luxel V-6: Replace the autoloader cover and the system reboots.

4. Luxel V-6 and V-6e: Open the user door and check if the following devices stop:

spinner

laser light

plate handling motors

vacuum pump.

5. Luxel V-6 multi-cassette: Check that the cassette door lock operates by running a Change Cassette procedure using information in the User’s Guide.

6. While the interlocks are enabled, check that the correct Error Handling screen and error code appears when a cover is opened, and the machine fully reboots when the cover is replaced:


572: engine user door opened

579: autoloader top cover removed

Error code 577 indicates that the interlock system has failed. Run the following utility to check for the cause:


5.2.4 Check Engine Traverse Level

NOTE: Check the level after the installation and again if there are signs of the Engine feet settling to a lower level.

Use this procedure to run a service utility that checks if the Engine is level from the traverse end-to-end. The aim is to minimise the amount of ball cage creep as the carriage continually moves back-wards and forwards along the rail. If there is a risk of the Engine settling into a soft floor surface, then repeat the check after 24 hours.

1. Insert the interlock override actuator (key) into the door interlock switch on the user side.

2. Check that the spinner and traverse are disabled. (They are enabled if the Engine application has been running). Select the following:

diagnostics/service/spinner/stop diagnostics/service/traverse/halt

3. Align the ball cage and carriage rail, see Figure 5.1 on Page 5-6 below.

4. Measure the distance between the end of the carriage rail/ball cage and the end of the V-groove, see Figure 5.1 on Page 5-6 below.

5. Run the datum utility:

traverse> datum6. Run one of the following tests that moves the carriage 20 times

up and down the beam length:

diagnostics/service/traverse/trav_test

if the carriage and ball cage were aligned at the service end, or enter:


diagnostics/service/traverse/trav_test R

if the carriage and ball cage were aligned at the user end.

Figure 5.1 Check traverse level

7. Release the traverse servo-drive by entering:

diagnostics/service/traverse/halt8. Align and measure as in steps 3. and 4. above.

9. If the difference between the measurements is greater than 0.5 mm, then an Engine level adjustment is required:

Adjust the feet to minimise creep and obtain an improved level. A small adjustment of 1/4 to 1/2 turn (0.25 to 0.5 mm) on the engine feet is usually sufficient.

10.Repeat steps 2. to 9. until creep is within the specification.

11. While the carriage moves along the traverse, observe the readhead LED from the user end and ensure that it remains green (and does not flash) for the full traverse. Ignore the red limit lights at the service end.

CARRIAGERAIL

BALL CAGE

ALIGN ANDMEASURE

RUN TRAV. TEST

MEASURE AND CORRECTFOR CAGE CREEP

3

1

2

V-GROOVE


NOTE: Checking the readhead LED is best carried out in dark or white light conditions. The LED is difficult to read in a safelight environment.

1. Set the correct trolley level by adjusting the four jacking screws.

2. Clean the Engine and plate loading platform.

3. Load and eject a plate into the drum using:

Manual, semi-automatic and single-cassette system: use the Media Tools option from the MMI or the PCI.

Multi-cassette system: use the Change Cassette procedure to load a cassette and use RUN mode to advance plates.

4. You will need to create new media from the PCI before it can be selected from the MMI or the PCI. Check the following:

A) The plate enters the drum without damage.

B) The interleaf sheet enters the bin (autoloader only).

C) The plate conforms without damage at the registration pins and pull bar shoes.

D) The plate exits the drum without damage.

E) The plate transfers to the processor without damage or skewing.

F) The plate is not scratched on either side and the edges are not damaged.

5. If any of the above checks fails, refer to the Engineer's Reference Guide for details on how to adjust mechanisms.

5.2.5 Set up the Processor (if Installed)An RS232 communications link setting between the engine and the processor allows the two units to share the same protocol for passing diagnostics and media handling commands.

1. Ensure that the link is enabled from the PCI menu.

2. Check that the processor and engine are able to pass messages by entering:

diagnostics/service/medproc/status3. Set the Processor plate thickness:


medproc/thickness [value]

where the [value] is the plate thickness (in μm) as:

0.15 = 1500.20 = 200

0.24 = 240

0.30 = 300.

4. Check in the processor display that the processor pre-heat temperature zones change as plates of different thickness are changed:

0.15 = P1 (G&J)0.20 = P2 (G&J)0.24 = P3 (G&J)0.30 = P4 (G&J)

5.3 Setting up Optics and Imaging

NOTE: Resolutions used for generating optics test patterns are built into the machine and are not dependent on the licenced resolutions.

5.3.1 Check Beam FocusThis procedure allows you to verify and change the NVRAMs for the Beam Converter Focus (BCF) mechanism so that it moves to the optimum focus position for all resolutions (res) and plate thicknesses.

1. Load a large plate (at least 600 mm high and 500 mm wide) and return to RUN mode.

NOTE: The engine must be in RUN mode otherwise the test pat-tern will not expose.

2. In diagnostics find and record the RIP exposure ND settings for 48 resolution shown in Figure 5.2 on Page 5-9:

nvram>dnv ND_RES48_RIP_EXPOSE


Figure 5.2 RIP exposure settings: 48 resolution

3. In diagnostics find and record the RIP exposure ND settings for 96 resolution shown in Figure 5.3 on Page 5-9:

nvram>dnv ND_RES96_RIP_EXPOSE

Figure 5.3 RIP exposure settings: 96 resolution

4. Navigate to the V6 Optics Setup screen:

optics>mmiThis displays the V6 Optics Setup Screen as shown in Figure 5.4 on Page 5-9. Navigate to the Final Values input and press y to select YES, This will display the (Final Values) V6 Optics Test Results Screen shown in Figure 5.5 on Page 5-10.

Figure 5.4 Optics Setup screen


Figure 5.5 Final Values screen

5. In the Final Values table, set the 48 resolution ND value to the 48 resolution value recorded in step 1.

6. In the Final Values table, set the 96 resolution ND value to the 96 resolution value recorded in step 2.

7. Save and exit.

8. Load a large plate.

9. Run the Auto-focus Test:

main>diagnostics/service/optics

optics>mmi

Set the Test defaults to Y. Press return then start the scan.

The Auto Focus check (see Table on page 11) runs three sets of test strips called:

1. Focus 96V (vertical lines, 2 on 2 off 96 res)

2. Focus 96H (horizontal lines, 2 on 2 off 96res)3. Focus 48V (vertical lines, 1 on 1 off 48res).


The plate will eject when the test is complete.

10.Process the plate to reveal the three sets of test strips:

The first two sets are for 96 resolution.

The third set is for 48 resolution.

Table 5.1 Beam focus check

AUTO FOCUS MACRO:

RUN TEST STRIPS

Focus 96V Focus 96H Focus 48V

Set Defaults? Yes N/A N/A

Scan Start Posn (mm) 10 N/A N/A

Strip Width (mm) 8 8 12

Start Value -900 -900 2500

Step Value 50 50 200

Number of Steps 13 13 11

Resolution 96 I/mm 96 I/mm 48 I/mm

Pattern Type Vert Hor Vert

Lines 2on 2off 2on 2off 1on 1off

Start Scan Yes Runs as Auto Runs as Auto


5.3.2 Calculating Values for 96 Resolution Test Strips

Figure 5.6 96 resolution test strips

NOTE: Figure 5.6 on Page 5-12 shows the Focus 96V and Focus 96H test strips. Each set consists of 13 strips 8 mm wide. The focus setting for each strip is shown here for illustrative pur-poses only and will not appear on the exposed plate.

1. For the Focus 96V set of strips, measure the density at the top of each strip to find the strip with the lowest density.

Select the focus setting for the lowest density test strip.

NOTE: The start value is -900 and the step value is 50 in this example.

2. Measure the density mid-point down each of the thirteen strips to find the strip with the lowest density.

Select the focus setting for the lowest density strip.

3. Measure the density at the bottom of each strip to find the strip with the lowest density

Select the focus setting for the lightest strip.

The three recorded values should all be within 150 of each other.

TOP

MID-POINT

BOTTOM

FOCUS 96HFOCUS 96V


4. Repeat steps one to three for the second set of Focus 96H test strips. All six recorded values (first and second test strips) should be within 150 of each other, if not, check the plate again to confirm your recorded figures.

5. Calculate the average of all six values recorded so far. The resulting average is the focus setting for 96 resolution for the plate thickness tested.

6. Calculate focus values for other plate thicknesses as follows:

Find the focus step positions for each remaining plate thickness by calculating the offset values from Table 5.2 on page 13 as fol-lows:

A) for instance, if a 96 res 0.15 plate gives –600, then a 0.30 plate gives –525, or

B) for instance, if a 96 res 0.24 plate gives –750, then a 0.15 plate gives –795.

Table 5.2 Focus Positions for plate thickness at 96 resTested Plate

Thickness (mm):Offset for

Plate:Focus Offset Value:

0.15 0.2 Add 25

0.24 Add 45

0.3 Add 75

0.2 0.15 Subtract 25

0.24 Add 20

0.3 Add 50

0.24 0.15 Subtract 45

0.2 Subtract 20

0.3 Add 30

0.3 0.15 Subtract 75

0.2 Subtract 50

0.24 Subtract 30


NOTE: The focus offset is 1 step per 2 μm change in the plate thickness. Thinner plates should have lower focus numbers.

Enter the 96 resolution values into the 96, 100, 144, 2400 and 3600 BCF positions in the Final Values Table.

5.3.3 Calculating Values for 48 Resolution Test Strips

Figure 5.7 48 resolution test strips

NOTE: Figure 5.7 on Page 5-14 shows the Focus 48H test strips. This set consists of 11 strips each 12 mm wide. The focus set-ting for each strip is shown here for illustrative purposes only and will not appear on the exposed plate.

1. Measure the density at the top of each strip to find the strip with the lowest density.

Select the focus setting for the lowest density test strip.

NOTE: The start value is 2500 and the step value is 200.

2. Measure the density mid-point down each of the thirteen strips to find the strip with the lowest density.

Select the focal setting for the lowest density strip.

3. Measure the density at the bottom of each strip to find the strip with the lowest density

TOP

MID-POINT

BOTTOM


Select the focus setting for the lightest strip.

The three recorded values should all be within 400 of each other, if not, check the plate again to confirm your values.

4. Calculate the average of all three values recorded so far. The resulting average is the focus setting for 48 resolution for all plate thicknesses.

5. Enter the resulting resolution value into the 48, 50 and 1200 BCF positions in the Final Values Table for all plate thicknesses. For the low resolutions, the focus does not depend on plate thickness as the depth of focus is higher than for the high resolutions.

6. Save and exit the Final Values Table and Optics>mmi.

7. Save NVRAM if any changes have been made.

8. Run linearisation to verify that the dots% are correct.

NOTE: If any of the focus conditions cannot be met, try a differ-ent value for ND and check the processor setup. Finish the required setups as well as possible and check the resulting quality using an S&T page. If the results are still unsatisfactory and cannot be improved, consult FFEI Customer Services.

5.3.4 Calibrate for Laser Exposure

5.3.4.1 MMI Menus (Luxel V-6)Exposure calibration sets up a constant exposure power level at the drum surface for all resolutions. The required exposure level is entered from the MMI. A recommended value is 50 which can be edited but only after advice from the plate supplier. This value corresponds to 65 μJ/cm2 for 1200, 48, 50res and 90 μJ/cm2 for 2400, 96, 100, 3600 and 144res.

1. From the MMI console (if fitted), display the TOOLS menu and press Exposure Calibration (lower righthand side button) to obtain the Exposure Calibration screen:


Figure 5.8 Exposure Calibration screen: MMI

2. Make a note of the current ND values in the Exposure Information screen

3. Press Start Calibration to measure the exposure level at the drum and calculate the ND settings of the filter wheel for all resolutions.

4. The screen shows a Wait Timer icon during the calculations and then indicates:

A) Successful calibration: a tick appears on the Exposure Calibration screen. None of the resolutions have failed.

B) Failed calibration: an ND Values screen appears, see Figure 5.9 on Page 5-17, showing a Warning icon next to the resolution(s) that failed because maximum available power has been exceeded. If any of these resolutions are used by the customer then clean the spinner mirror and repeat the calibration.

If the spinner clean utility is run from the MMI or PCI, expo-sure calibration is performed automatically during the engine reboot.

Call FFEI Customer Support (UK) if the calibration fails again.

The ND Values screen only appears if there is insufficient power at one or more resolutions. To view the ND values

EXPOSUREINFORMATION

STARTCALIBRATION

CURRENTEXPOSURELEVEL

EDIT EXPOSURELEVEL


screen, press the Exposure Information button.

Figure 5.9 ND Values screen: MMI

NOTE: The ND settings for exposing RIP images are stored directly on the Engine and are not supplied by the RIP.

When exposure calibration has been performed, linearise the per-centage dots at the required resolutions and screen rulings using the RIP Calibration Manager.

5.3.4.2 PCI Menu (Luxel V-6e)Check exposure calibration from the PCI menu using information from Section 5.3.4.1 on Page 5-15 above and Luxel V-6 Series PCI User’s Guide.

5.3.5 Check Registration and Tint QualitySee the Luxel V-6 Series PCI User’s Guide and Engineer's Reference Guide.

These commissioning procedures check for:

tint quality (50% tint prediction test)

plate registration.

47 9448 9450 9394 8696 85100 85141 76144 75

TIME SINCE LAST CALIBRATION(HOURS:MINUTES)


5.3.5.1 Check Plate RegistrationUse the following procedure to check that registration is within the specified limit (see Figure 5.10 on Page 5-18):

1. Expose and process a grid image from the PCI Diagnostics (Stock Images folder) menu which gives vertical and horizontal lines.

Use the largest possible plate size for this procedure, for example, 765 x 686 mm.

Figure 5.10 Plate registration check

2. Check that the bow on the scan lines is less than 50 μm. Use the supplied film grid/straight edge (or glass ruler) to measure the bow at the widest point.

3. Check for image squareness and diagonal accuracy by measuring A and B. The difference between the two values must be less than 100 μm.

4. If the difference is less than this value then the plates are properly registered. If it is not, then follow the Registration Correction procedure in the Luxel V-6 Series Engineer's Reference Guide.

5.3.5.2 Expose a 50% Prediction Test Plate1. Expose and process a tint page from the PCI Diagnostics (Stock

Images folder) menu using:

A) 765 mm x 686 mm plate, or

GRID IMAGE

PLATE

A B


B) use the largest plate available on-site.

2. Using a densitometer, check at the nine plate points shown in Figure 5.11 on Page 5-19 and recalibrate the densitometer at each point.

Background points (reference) are at 0 %.

Saturated points (reference) are at 100 %.

Tint points are all equal within +/- 1%.

Figure 5.11 50% Tint predict check

IMAGE

TINT(50%)0% 100%


3. Failure to achieve uniformity of ±1% could be caused by:

dirty spinner

incorrect focus adjustment

poor mechanical/vacuum conformance

gum on plate increases dot% by 3% – 4%poor processor conditions for:

A) pre-heat

B) developer pH reading should be 12 ±0.25 (11.75 to 12.25)

C) process time

D) developer scrub pressure.

Consult FFEI Customer Support to resolve a non-uniformity fault.

5.3.5.3 Test Image Quality1. Expose an S&T image from the PCI Diagnostics menu (Stock

Images folder) at the fixed resolution of 96 and test the image quality for:

screen quality

raster quality

vignette quality

dot prediction accuracy

highlight dot quality.

2. If any issues are detected then refer to the Luxel V-6 Series CTP Engineer's Reference Guide.

3. If the issue cannot be resolved then contact the FFEI Customer Support (UK).

5.3.6 Check Edge Detect FunctionSee the Luxel V-6 Series Engineer’s Reference Guide for details on the full Edge Detect setup.

Check the plate edge detect function as follows:

1. Enter the commands:

diagnostics/service/traverse> halt


diagnostics/service/traverse> medirq

Check that the Edge Detect PCB laser beam is ON.

2. Load a plate into the drum and move the traverse by hand so that the edge detect beam moves across the plate edge.

3. Check that the LED on the Edge Detect PCB is OFF when the beam is on the plate and ON when the beam is on the drum.

4. Press Ctrl-c to exit medirq.

5. Reboot the Engine.

5.4 Checking Plate Output (without a Punch)See the Luxel V-6 Series CTP User’s Guide and Engineer’s Refer-ence Guide.

These procedures apply to a platesetter without a punch and check for:

Image skew accuracy: see Section 5.4.1 on Page 5-21.

Image start and edge accuracy: see Section 5.4.2 on Page 5-22.

Image base offset: see Section 5.4.3 on Page 5-23.

5.4.1 Check Image Skew Accuracy

NOTE: This check only needs to be made if image skew is noticeable.

Use fitted registration pin centre points for these skew measure-ments as plate edge quality varies across the plate.

1. Expose a tint on a 765 mm x 686 mm plate, or use the largest plate available.

2. With a steel or glass ruler, measure reference lines A and B using, at least, a x50 eyeglass with a measurement graticule fitted, see Figure 5.12 on Page 5-22.

3. Check that the difference between the two lines is less than or equal to ± 50 microns.

4. Expose and measure 4 plates and check that repeatability is less than or equal to ± 25 microns.


5. A possible cause of error is a poor pullbar adjustment. Information on the pullbar adjustment is in the Luxel V-6 Series Engineer’s Reference Guide.

Figure 5.12 image skew check

5.4.2 Check Image Base and Edge Accuracy1. Expose a tint on a 765 mm x 686 mm plate, or the largest plate

available on-site.

2. Check that the distance between the image base and edge start positions as shown in Figure 5.13 on Page 5-23 below.

3. Measure from the registration pins (A and B) for the image base offset.

4. Measure 67 mm down from the plate top for the image edge offset position on the lefthand side.

5. If required, move the image base using the procedure in Section 5.4.3 on Page 5-23.

IMAGE

PLATE

A B

REGISTRATION PINS

CENTRE OFPLATE


6. If required, move the image edge offset direction using the procedure in Section 5.4.4 on Page 5-24.

Figure 5.13 Image edge detect accuracy

5.4.3 Set Image Base Offset

NOTE: The image traverse centre position is factory-set and should not need to be adjusted during an installation.

This procedure adjusts the non-imaged area at the top of the plate.

1. Expose a tint image from the PCI Diagnostics menu on a 765 mm x 686 mm plate, or the largest plate available on-site.

2. Check for the default area shown in Figure 5.14 on Page 5-24.

3. Modify the value of the IMAGE_BASE_OFFSET until the top of the plate to the image is 2 mm (Non-punch) and typically 12 mm (punch). Use the following menu:

optics> mmi

IMAGE

PLATE

A B

67 mm2 mm ( NON-PUNCH) TYPICALLY 12 mm (PUNCH)-

2 mm( + 25 μm)-


Enter Machine Setup and adjust the value of the Image Base Offset (microns).

To move the image nearer the registration pins, reduce the value.

To move the image away from the pins, increase the value.

Figure 5.14 Setting the image base offset

5.4.4 Set Image Edge Offset 1. Open the optics_mmi setup screen from:

optics> mmi2. Run a test pattern with the Scan Start position as 0 mm.

3. Eject and process the image and check that it is 2 mm from the lefthand edge of the plate, measured 67 mm down from the top as shown in Figure 5.13 on Page 5-23.

4. If it is not then find the current parameter EDGE_SENSOR_OFFSET value (in microns) as follows:

optics> mmi5. Using Machine Setup, find the current setting for Edge Sensor

Offset.

IMAGE

PLATE

STARTSCANPOINT

NON-PUNCH)

TYPICALLY 12 mm(PUNCH)

IMAGE_BASE_OFFSET = 2 mm


If the image is more than 2 mm from the plate edge then decrease the parameter value.

If it is less than 2 mm then increase the parameter value.

6. Repeat these steps until the edge of the plate to the image start position is 2 mm.

5.5 Checking Plate Output (with a Punch)These procedures apply to platesetters with a punch and check for:

Punch configuration: see Section 5.5.1 on Page 5-25.

Image skew accuracy: see Section 5.5.3 on Page 5-28 and Sec-tion 5.5.2 on Page 5-27.

Image base position in RIP: see Section 5.5.4 on Page 5-29.

Punch centering: see Section 5.5.5 on Page 5-29.

5.5.1 Punch Configuration CheckCheck that the punch configuration matches the example shown in Figure 5.15 on Page 5-26.


Figure 5.15 V-6 punch option configurations

8 mm

PUNCH A 6.35 mm x 9.525PUNCH B 12.68 mm x 10PUNCH C 12 mm x 14.68 mm

HEIDELBERG + BACHER

425 mm

393 mm

220 mm

A A

B CBB

11 mm

A = BACHERB = HEIDELBERGC = HEIDELBERG

DS400

400 mm

A B

8 mm

PUNCH A 6PUNCH B 6 mm x 8

KOMORI

550 mm

A B

PUNCH A 12 mm x 12 mmPUNCH B 11.19 mm x 8

9 mm

305 mm

A A

259 mm *

A A

REGISTRATION PINS

REG PIN A 14

* SEE NOTE

NOTE: EARLY MACHINES: REG PINS AT 259 mm USED ONLY WHEN SMALL PLATE OPTION FITTED.LATER MACHINES: 259 mm REG PINS USED FOR ALL PUNCH SYSTEMS.


5.5.2 Check Image to Top of Plate Accuracy


Check image to top of plate accuracy as follows:

1. Expose 4 plates with a 50% tint stock image.

2. Move the image (usually set at 2 mm) as close as possible to the top edge of the plate using the following method:

A) Adjust the IMAGE_BASE_OFFSET value in the diagnostics/service/optics/mmi> machine setup screen after noting the original value to be restored.

B) For instance, if the value is approximately 1339850 microns, move it closer to the plate edge by subtracting 2000 microns (1337850).

C) Adjust the gap +/- a few microns to obtain a measurable difference.

3. Using a x50 eyeglass, measure the gaps, A and B, at the widest reg pin positions (259, 305 or 470 mm), see Figure 5.16 on Page 5-27.

Figure 5.16 Image to top of plate accuracy check

IMAGE

PLATE

A B259 mm


4. Calculate the skew over the full plate width as follows:

Skew = (A-B) x plate width in mmReg pin distance in mm (259, 305 or 470)

5. Skew should be less than 50 microns on each plate.

6. Possible skew errors could be caused by poor pull bar alignment - see the alignment procedure in the Luxel V-6 Series Engineer’s Reference Guide.

5.5.3 Check Image to Punch Crop Accuracy


Check image to punch crop accuracy as follows:

1. Expose 4 plates with the 50% tint stock image.

2. Using a glass or steel ruler (with a x50 eyeglass), measure the reference lines, A and B, at the widest crop points of each plate, see Figure 5.17 on Page 5-28.

You can move the image up or down to allow easier measurement by using the method in Section 5.5.2 on Page 5-27 (Step 2).

Figure 5.17 Image to punch crop check

IMAGE

PLATE

A B


3. Skew error differences between the measurements A and B should be less than 100 microns for each plate.

4. Possible skew errors could be caused by poor pull bar alignment - see the alignment procedure in the Luxel V-6 Series Engineer’s Reference Guide.

5.5.4 Check Image Base Position in RIPCheck that you can move the image base relative to the lead edge from the Start Y option on the RIP Job Ticket (Output) panel.

Set the position at 0 and the Y position corresponds to 2 mm from the leading top edge of the plate. To move the image away from the crop marks in the Y direction, add a small amount.

5.5.5 Check for Image Centering1. Check that the image is centered on the plate.

2. Make sure the image is centered at equal distance (A and B) from the outer crop marks shown in Figure 5.18 on Page 5-29.

Figure 5.18 Centering the image (with punch)

PLATE

A B

IMAGE

PUNCHCENTRE


5.6 Installing the Remote Alert Forwarding The V-6 Alert Forwarding system operates as an option within the Luxel Desktop software (1.2 and later). Once enabled, it runs as a PC background utility to detect and report errors from the output engine. Alert messages indicating a system error are sent directly from a local host server (or an external ISP host) to a designated PC and/or mobile phone as an email.

Alert messages from the V-6 engine are based on the same set of PCI Dashboard errors that appear as code numbers on your PC when the output system requires attention for a fault. A full list of the possible errors and recovery procedures for the user are in the Luxel V-6 Series User’s Guide.

NOTE: See a local mobile service provider for more information on relaying email text messages to a mobile number.

5.6.1 PreliminariesBefore configuring the RIP PC email application for Alert Admin, make sure the following preliminary steps are completed.

1. Load the Luxel Desktop (see Section 4.7.2 on Page 4-59). Make sure any previous versions of the Desktop software have been removed beforehand.

2. Reboot the RIP PC.

3. Open the Services window from:

Start > Settings > Control Panel > Administrative Tools > Services

Check that LuxelListener has started and is running in the background. The remote system will not operate without LuxelListener.

4. Open the Remote Alert window from:

Start > Programs > LuxelDesktop X.X > Alert Admin

This shows the following menu bar:


Figure 5.19 Remote Alert menu bar

5. The remote alert system is enabled for use by selecting:

Remote Alert > EnabledThis global enable option allows the operator to switch the alert system ON/OFF to start or stop alerts.

Leave this selection disabled when configuring remote alert.

5.6.2 Setup the Mail Configuration1. Disable the remote alert.

2. Select Mail > Mail Configuration to open the Mail Configuration window, see Figure 5.20 on Page 5-32.

3. Enter the From URL for your emails.

For web-based mail servers this will be the email address you registered with. For most, if not all, web-based mail servers this address must be entered in the ‘From Address’ field of any mail message. Most will not deliver emails with an unregistered ‘From Address’. Check the mail forwarding details for your particular host.

MailConfiguration


Emails are always sent via an SMTP mail host. Even if using POP authentication you must still define the SMTP host.

Figure 5.20 Mail Configuration window

5.6.2.1 Local Mail Server:1. Obtain the mail server URL from the site IT administrator.

2. Enter this address in the SMTP Mailhost field.

3. Enter the SMTP TCP/IP Port number suppled by the site IT administrator.

5.6.2.2 Web-Based Mail Servers1. Enter the SMTP Mailhost name for this server.

2. Enter the SMTP Port number for this server.

5.6.2.3 SMTP Authentication1. For a local mail server check if authentication needs to be enabled

if the alert is routed via a third-party server. If it is then obtain the User ID and password from the site IT administrator.


2. Tick the SMTP Authentication check box, see Figure 5.21 on Page 5-33.

3. Enter the supplied ID in the User ID field below.

4. Enter the password in the Password field.

5.6.2.4 Web-Based Mail Host1. Use the User ID and Password for the mail account.

2. Tick the SMTP Authentication check box, see Figure 5.21 on Page 5-33.



Figure 5.21 SMTP Authentication window

5.6.2.5 POP Authentication

5.6.2.5.1 Local Host:1. Check the POP Authentication box, see Figure 5.22 on Page 5-34:


Figure 5.22 POP Authentication

2. Obtain the POP mail server URL from the site IT administrator.

3. Enter this address in the POP Mailhost field.

4. Enter the POP TCP/IP Port number supplied by the site IT administrator. For a local mail host this will normally be 110.

5.6.2.5.2 Web-Based Mail Servers:1. Enter the POP Mailhost name for this mail host.

2. Enter the POP Port number for this mail host.

3. For a local mail server obtain the user ID and password from the site IT administrator.



5.6.2.5.3 Web-Based Mail Host:1. Obtain the User ID and Password for the Mail account.




5.6.3 Configure the Alert System1. Select View > Destinations window to set the destination of the

operator receiving the alert.

2. Click on Create to open a window when the destination is a mobile:

3. Enter the following:

Description: name of the operator receiving the alert.

URL: URL of the mail recipient.

Format: select from the drop-down menu the type of alert:

Short: a very short description of the error in English or a translated version, normally used for mobile text.

Brief: includes a message for email, a full error description and a copy of the machine HTML page describing the error.

Full: similar to Brief but with more information.

NOTE: Do not select Brief or Full for mobile messages.


4. Click on Create and Close, highlight the Name line and click on the Enabled check box. If there are other operators available to receive alerts then also add their destination details. Operators can be enabled and disabled depending on their work shifts.

Select Edit or Remove to alter or remove the Name details from the Destinations window.

5. Select View > Errors to open the Errors window for enabling individual machine errors that raise an alert message.


6. Select the errors requiring an alert and click on Enabled check box. For instance, to check for an error message, select 572 (user


open door error) and open and engine door. The system will beep and then send the error report.

7. Save and Close the window.

8. Click on Test and open the Test Destination window to check if the alert forwarding system is correctly configured.

9. Click on Send to route a test email to the destination URL.

10.Enable the remote alert and exit.

DEMONSTRATING THE LUXEL V-6SYSTEM

6.1 Demonstrate the PlatesetterAs a final task, the installation engineer (or a qualified represent-ative) needs to give the customer a brief description of the plate-setter's main features. The aim is to ensure that the customer understands how to:

Operate the system safely, productively and efficiently.

Develop practices to ensure the long-term reliability of the product.

This chapter describes how to demonstrate to customer the main oper-ating features of the Luxel V-6e and V-6.

6.1 Demonstrate the Platesetter................................................................ 6-16.2 Platesetter Safety and Interlocks........................................................ 6-26.3 Using the MMI (V-6 Option) and PCI ................................................... 6-26.4 Platesetter Maintenance ...................................................................... 6-36.5 Recovering From Platesetter Errors................................................... 6-46.6 Loading Cassettes (Single- and Multi- Cassette) .............................. 6-56.7 Running the RIP.................................................................................... 6-5

6-2 DEMONSTRATING THE LUXEL V-6 SYSTEM

Decide when an error condition has occurred.

Recover from an error condition.

6.2 Platesetter Safety and Interlocks

6.2.1 Laser SafetyThe customer should be aware of the main safety interlocks and their function in preventing the laser beam from damaging eye-sight.

They should also understand that user access to the engine is only from the user side.

6.2.2 Electrical SafetyElectrical and mechanical safety features need to be explained for situations where the customer has to open the platesetter to access plates or commence a maintenance procedure. Explain how the customer is protected by the interlock system if one of the user covers are opened.

6.2.3 Mechanical SafetyMake sure the operator is aware of the following caution.

CAUTION: Do not manually move cassettes between the autoloader and the autofeeder. Any movement of cassettes are recorded by the machine while the system is operating to ensure that all mechanical changes are run safely while the cassette is in a known location.

6.2.4 Accessing the PlatesetterExplain the covers and doors accessible to the user, and the covers and doors accessible only to the service engineer.

6.3 Using the MMI (V-6 Option) and PCIShow the customer how they can navigate the MMI/PCI menus between the two modes of operation: RUN and PAUSE. Explain


the options available for each mode.

6.4 Platesetter MaintenanceTake the operator through the maintenance procedures in the Luxel V-6 Series PCI User’s Guide.

6.4.1 Emptying the Chad Tray (Luxel V-6 with Punch)

Show how the tray is removed and re-inserted.

6.4.2 Emptying the Interleaf Bin (Single- and Multi-Cassette)

Show how the bin is emptied and how to confirm the empty bin.

6.4.3 Cleaning the Spinner MirrorDemonstrate how the spinner mirror is cleaned with the pre-ferred cleaning materials, and emphasise the dangers of damag-ing the mirror coating. Also, explain that the L6 lens must not be touched.

Make sure they understand that Exposure Calibration is carried out automatically after the mirror is cleaned. They need to re-lin-earise from the RIP afterwards.

6.4.4 Checking the Platesetter EnvironmentMake sure the customer understands why the temperature and humidity of the platesetter room and the plate store room need to be within the specification given in the Luxel V-6 Series PCI User’s Guide.

6.4.5 Vacuum Clean the PlatesetterShow the customer how and when to vacuum clean the interior of the platesetter and cassettes. Areas for particular attention are:

drum interior - using a vacuum cleaner or lint-free cloth


cassette recesses - emphasise the need to keep the cassette lid closed, except when the plate is being loaded.

Make sure the customer is aware of the problem of dust and does not open the platesetter doors or covers unnecessarily. Emphasise the importance of keeping the platesetter room clean.

6.5 Recovering From Platesetter ErrorsEnsure that the operator is aware of all the MMI/PCI alert icons and the error codes that indicate a platesetter problem. They should understand the type of faults (media jams, etc) that can be corrected by the operator and the faults that require a telephone call to the local support centre.

6.5.1 Operator Recovery From Media Jams Describe how a jammed plate is removed from the autoloader and engine.

While recovering from a media jam, make sure the customer understands:

The importance of wearing the correct type of gloves for han-dling plates.

How jammed plates are manually recovered from the drum, the punch, the input and output modules.

Output delays may be caused by the processor adjusting chem-ical temperatures for different plate types loaded on-demand by a job.

6.5.1.1 Recovery From System ErrorsSystem faults (electrical, optical, etc) are usually interpreted by error codes that appear on the MMI/PCI. Customers should be advised to note the code number and call the local Distributor customer support.


6.6 Loading Cassettes (Single- and Multi-Cassette)

Demonstrate how to load a cassette with plates and show how the cassette is installed in the autoloader.

NOTE: Make sure the operator understands how the cassette lid is fitted to avoid plate handling problems.

If a manual loading slot has been fitted then demonstrate how the plate is advanced with the MMI options.

6.7 Running the RIPExplain how the RIP interface operates using information from the supplied RIP Documentation. Further information on machine error codes for the operator is available from the PCI User’s Guide.

6.7.1 Switching On/Off SequenceExplain how the platesetter system (processor, RIP and engine) is switched ON and OFF.

6.7.2 Calibrating the Platesetter OutputRun the RIP Linearisation calibration procedure - see the RIP Doc-umentation for the system.

6.7.3 Ordering New OptionsExplain how the customer can order new options from the list dis-played from the PCI option.


Fuji V6 Installation

Documents

external manufacturer

support packand

electromagnetic

based mail

pat air filter

base earth

remote alert

diverter transit