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MAKO 2 CTP, MAKO 2x CTP,Operator Guide
MAKO 4 CTP, MAKO 4x CTP, and MAKO NEWS CTP
AO111334Revision 2
Operator GuideMAKO 2 CTP, MAKO 2x CTP,MAKO 4 CTP, MAKO 4x CTP
and MAKO NEWS CTP
© copyright ECRM Incorporated 2008
Additional copies of this guide may be obtained by writing or calling:
ECRM Order Processing554 Clark Road
Tewksbury, MA 01876
Phone No. (US) - (+1) 978-851-0207 — Fax (US) - (+1) 978-851-7016 Phone No. (UK) - (+44) 1923-218255 — Fax (UK) (+44) 1923-218256
Phone No. (Hong Kong) - (+852) 2-564-8989 Fax (Hong Kong) (+852) 2-564-8821
Visit our Web site: www.ecrm.com
Proprietary Notice
The information contained in this publication is the sole property ofECRM. It cannot be reproduced, in whole or in part, without the expresswritten consent of ECRM. The information is believed to be accurate as ofthe publication date, but it is subject to change without notice due tocontinuing product development.
ECRM® and MAKO® are trademarks of ECRM Imaging Systems. Otherbrand and product names are trademarks or registered trademarks of theirrespective owners.
AG111
Table of Contents
Table of Contents iiiPreface vScope of this Guide vOrganization vTerms and Conventions vi
System Overview 1The MAKO CTP Series 1Functional Overview 1System Components 3Main Parts of the Platesetter 5System Requirements 8Laser Safety 9Regulatory Information 10
System Operation 13Introduction 13Starting Up the System 13Shutting Down the System 14Using the Control Panel 14Operator Menus 16User Preference Menu 17User Maintenance Menu 22Test Patterns Menu 24Equipment Configuration Displays 29Display Messages 30Running a Step Wedge Test 31
Media Handling 37Media Specifications 37Safelight Requirement 37Installing and Removing the Pin Bar 38Loading Media 42
334 Rev. 2 iii
Maintenance and Troubleshooting 53Introduction 53General Maintenance 53Clearing Misfeeds, Manual Pinch Mechanism 58Moving the System 61
iv AG111334 Rev. 2
PrefaceScope of this Guide
This guide explains how to operate and maintain MAKO CTP series platesetters. The guide describes all aspects of operating a system.
All platesetters in the series use a Class Four laser. This guide contains important safety information and regulatory information about the laser. You should read this information thoroughly before operating the system or performing the procedures described in this guide.
This guide assumes the system is already properly installed and plugged into the AC mains, and that the system has been calibrated and tested for proper operation and acceptable output.
Organization
Chapter 1: System Overview
This chapter presents a system overview. It includes system operating requirements and information about laser safety.
Chapter 2: System Operation
This chapter explains the operational features and describes the system menus in detail. All of the menu items are mapped in flow diagrams.
AG111334 Rev. 2 v
Chapter 3: Media Handling
This chapter provides instructional information on how to load media. Guidelines for handling media are also provided.
Chapter 4: Maintenance and Troubleshooting
This chapter covers general maintenance items that can be performed by the operator. This chapter includes troubleshooting tips and a procedure for re-locating or moving the system.
Terms and Conventions Because the systems in the series are so similar, no distinction between systems is made except where necessary. In this manual, except where otherwise noted, all references to “the platesetter” or “the system” pertain to any system in the series.
Text and terminology conventions in this manual are as follows:
“Type” Is an instruction to type data at the keyboard.
Italic typeface Used to indicate the first mention of an important concept.
Bold typeface Used to highlight important details in text or illustrations and to indicate user actions.
Bold sans-serif typeface Used to represent file names or menu options to be selected. Also refers to section names.
Note: Blocks of text used to advise of related information.
IMPORTANT Notices used to emphasize very important information.
vi AG111334 Rev. 2
1System OverviewThe MAKO CTP Series
The MAKO CTP series is comprised of the following systems.
• MAKO 2 CTP
• MAKO 2x CTP
• MAKO 4 CTP
• MAKO 4x CTP
• MAKO NEWS CTP
Functional OverviewAll the systems use a violet laser. MAKO 2, MAKO 2x, MAKO 4, and MAKO 4x are for commercial printing environments, whereas the MAKO NEWS is for newspaper publishing.All the systems perform the same basic functions and are operated the same way. The main differences between the systems include the imaging resolutions and media sizes they support, and the type of pinch mechanism they use (see the feature comparison tables on the next page).
Note: This manual makes no distinction between systems except where necessary. In the presentation that follows, except where otherwise noted, all references to “the plate-setter” or “the system” pertain to any system in the series.
AG111334 Rev. 2 1
Table 1 - 1 FEATURE COMPARISONS
MAKO 2 CTP
MAKO 4 CTP
MAKO 4X CTP
MAKO NEWS
3556304825402400203218001500127012001016
SYSTEM RESOLUTIONS
140.0120.0100.094.580.070.959.050.047.240.0
Notes:1. (W) and (L) designate the width and length of the plate in millimeters (mm).2. Edge Register: maximum plate size (edge to edge imaging) using an edge-register pin bar.3. Notch Register: maximum plate size (edge to edge imaging) using an notch-register pin bar. The notch register plate size
requires a minimum 12 mm notch depth, except System 4x, which requires a minimum 11 mm notch depth.4. Minimum Edge Register: Minimum plate size. The minimum plate size of 252 mm (L) requires a custom pin bar on all 4-page
machines.
SYSTEM PLATE SIZE (MM)Maximum
Edge RegisterMaximum
Notch RegisterMinimum
Edge Register560 mm (W) x 670 mm (L)
615 mm (W) x 745 mm (L)
635 mm (W) x 960 mm (L)
635 mm (W) x 960 mm (L)
560 mm (W) x 670 mm (L)
615 mm (W) x 745 mm (L)
635 mm (W) x 960 mm (L)
660 mm (W) x 960 mm (L)
228 mm (W) x 252 mm (L)
228 mm (W) x 252 mm (L)
228 mm (W) x 252 mm (L)
(DOTS PER INCH)
(DOTS PER MILLIMETER)
228 mm (W) x 252 mm (L)
SYSTEM PINCH MECHANISMAutomatic The platesetter automatically
manually open and close the pinch rollers.Manual The operator uses a pinch bar to
opens and closes the pinch rollers.
MAKO 2 CTP
MAKO 4 CTPMAKO 4X CTPMAKO NEWS CTP
MAKO 2 CTP
MAKO 4 CTP
MAKO 4X CTP
MAKO NEWS CTP
MAKO 2X CTP
560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 228 mm (W) x 252 mm (L)MAKO 2 CTP
MAKO 2X CTP
2 AG111334 Rev. 2
System ComponentsA complete system includes a control workstation, CtServer software, a power conditioner, and a platesetter.
Figure 1-1 System Components
PlatesetterThe platesetter images and outputs plates.
WorkstationThe workstation connects directly to the platesetter and runs the CtServer software. Operating instructions for the workstation are provided with the workstation. The operator makes frequent use of the workstation when running the platesetter. For that reason, the workstation should be set up next to the platesetter.
CtServer SoftwareCtServer is used to send jobs to the platesetter. It is also used to define the plate and pin bar requirements for jobs and communicate that information to the platesetter, which displays the information on the control panel LCD.
PIN BARS
CONTROL PANEL
TRANSPORT
CONTROLWORKSTATION*
* the monitor is ordered as an option
UNIT
IMAGINGUNIT
PLATESETTER
REGISTRATION
CT SERVERSOFTWARE
POWERCONDITIONER
AG111334 Rev. 2 3
Some operating parameters that can be set in CtServer can also be set at the control panel. For these parameters, the CtServer setting always overrides the control-panel setting. The use and operation of CtServer is documented in the CtServer User’s Guide, which is delivered as a PDF on the CtServer CD.
Power ConditionerThe power conditioner shields the system from as ac power spikes, voltage drops, and other electrical power disturbances. The platesetter, the control workstation, and the control workstation monitor must all be plugged into the power conditioner, which in turn must be plugged into a grounded ac power outlet.
Figure 1-2 System AC Power Wiring Diagram
Note: For the system to work properly, the platesetter, the CtServer workstation, and the computer monitor must all be plugged into the system power conditioner. Be advised that if the devices are not plugged into the power condi-tioner, damage resulting from voltage spikes, brownouts, etc., will NOT be covered by the warranty.
AC MAINSPOWER
AC OUTLETS
PLATESETTER WORKSTATION MONITOR
AC INLET
AC Power
AC Power
RS-232*
USB Monitor
(with CtServer)
CONDITIONER AC INLET
AC INLET AC INLET
Plate Line IF
AC Power
AC Power
Platesetter System
* Used by service personnel to run diagnostic programs.
PROCESSOR
Customer-suppliedPlate Processor
4 AG111334 Rev. 2
Main Parts of the PlatesetterPower Switch
The power switch controls ac power to the system. To start up the system, turn on the power switch. It is located on the rear right side of the machine. Depress zero (0) to turn OFF, depress one (1) to turn ON. See Figure 1-3 on Page 5.
Note: It is recommended that the system be powered on for a 1-hour warm-up period prior to imaging.
Figure 1-3 Main Parts of the Platesetter
Power CordThe power cord plugs into a receptacle located just below the power switch.
Pin BarThe pin bar is used for plate registration. There are two types of pin bars: press notch registered and edge registered.
POWER SWITCH
CONTROL PANEL
PINCH ROLLER BAR
MEDIA TRANSPORT
INPUT TRAYPEDESTAL
PIN BAR
POWER CORD
(NOT PRESENT IN MAKO4
BACK FRONT
AND MAKO NEWS)
OUTPUT SENSOR
INPUT SENSOR(NOT PRESENT IN MAKO 4 AND MAKO NEWS)
FAN FILTER
AG111334 Rev. 2 5
Two pin bars come with the system as standard equipment. Additional pin bars can be ordered as an option.
Exposing sets of plates with different registration notch requirements is easily accomplished by changing the pin bar.
Control PanelThe control panel allows you to interact with the platesetter. Commands and options are controlled through this device.
Input TrayThe input tray is used to position the plate for exposure. The plate is placed on the input tray and gently slid to engage the registration pins. A groove is provided in the surface of the input tray to provide a convenient place to push the plate forward. A plate cannot be loaded until the previous plate has been completed.
Pinch Roller Bar (MAKO 2 and MAKO 4)Note: MAKO 2x, MAKO 4x and MAKO NEWS models do not have
a pinch roller bar.
On MAKO 2 and MAKO 4 platesetters, a pinch roller bar is used to open and close the pinch rollers. These high precision rollers control the movement of plate during exposing. The pinch roller bar is raised (pinch rollers open) to load a plate and lowered (pinch rollers closed) to expose a plate.
Never raise the pinch roller bar while a plate is being exposed! Doing so will cause the plate to jam inside the platesetter if you are using an edge-registered pin bar.
Note: The pinch roller bar must be up during the initialization process after a power on.
6 AG111334 Rev. 2
Figure 1-4 Pinch Roller Bar
Fan FiltersThe platesetter uses 2 fan filters. The filters slide into slots on either side of the unit. See Figure 1-3 on Page 5.
Note: To avoid damaging the filters, when lifting the platesetter off the pedestal, do not grasp the platesetter at points where the filters are located.
The Media TransportThe media transport automatically delivers the exposed media to a customer-supplied online processor.
The PedestalThe pedestal is a specially designed base for the platesetter.
PINCH ROLLER BAR *
PINCH ROLLERS
* SHOWN IN THE UP (OPEN) POSITION
AG111334 Rev. 2 7
System RequirementsSafelighting
The platesetter is designed to be operated in a safelight environment.
Power and Heat DissipationPower (maximum) 90 - 264 Volts; 3 Amps; 250 Watt 50/60Hz, single phase.
Heat Dissipation 850 BTU/hour
Environmental Requirements Temperature- 62 - 86 degrees F (17 - 30 degrees C)
Humidity 45 - 65%, non-condensing.
Note: Operating the system outside of the ranges specified above may affect performance.
8 AG111334 Rev. 2
Laser SafetyLaser Product Classification
The system is classified as a Class one (I) laser product. This classification means the operator is not exposed to hazardous laser light during operation and maintenance. The laser in the system is a Class Four (IV) device which emits visible laser light that is considered hazardous by FDA published limits.
IMPORTANT WARNING
Use of controls or adjustments or performance of procedures other than those specified in this guide may result in hazardous laser light exposure.
System Laser Wavelength Identification LabelThe system uses a laser that emits visible laser light. The identification label is located on the output side of the machine, above the output rollers. Figure 1-5 shows the label.
Figure 1-5 Media Sensitivity Label
MEDIA SENSITIVITY405 nm VISIBLE
AG111334 Rev. 2 9
Regulatory InformationElectromagnetic Emissions
DOC - CanadaThe Canadian Department of Communications requires compliance with the Radio Interference Regulations, ICES -003.This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications.
EMC Directive - EuropeComplies with EN 55011: 1998This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures.
FCC - USAThe standards for electromagnetic emissions are Part 15, Subpart J of the FCC rules. The system was tested to Class A limits. The following statements are required by the FCC:Changes or modifications to this unit not expressly approved by the party responsible for compliance could void your authority to operate the equipment.This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction guide, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to
10 AG111334 Rev. 2
correct the interference at his or her own expense.Compliance with applicable regulations depends on the use of shielded cables. The user is responsible for procuring the appropriate cables.
Identification and Certification Label (ratings plate)The system identification and certification label is attached to the front of the unit, above the pinch rollers.
Figure 1-6 Identification and Certification Label
AG111334 Rev. 2 11
12 AG111334 Rev. 2
2System OperationIntroduction
The same basic operating procedures apply to all models in the series. Except where otherwise noted, all the information that follows pertains to every model in the series.
Starting Up the SystemThe power switch located on the rear right side of the machine.
Step 1. On the power switch, depress one (1) to turn the power ON. When the system completes its initialization, the ONLINE message appears on the display.
Step 2. After ONLINE appears, power up the control workstation.
Step 3. Once the workstation is powered up, invoke CtServer (or the RIP).
Step 4. Once CtServer (or the RIP) is running, the system is ready to image plates. For instructions on sending jobs to the platesetter, refer to the CtServer User’s Guide.
Note: It is recommended that the system be powered on for a 1-hour warm-up period prior to imaging.
AG111334 Rev. 2 13
Shutting Down the SystemShut down the system only when the display reads ONLINE, and the second line is blank. (No operational message visible). To shut down the system:
Step 1. Turn off the power switch located on the lower right side of the machine. Depress zero (0) to turn the power OFF.
Note: Once the platesetter is turned off, the control workstation’s communication link with the platesetter is broken. To re-establish the link, power down the workstation, restart the platesetter, and then power up the workstation.
Using the Control PanelWhen you install the system, you should review and set all the menu parameters. Advance through the menu parameters and verify or change them as needed.
Accessing Menus
Access menus from the system control panel. Enter the menu sub-system by pressing MENU from the ONLINE state.
PREV NEXT
MENU SELECT
LCD
OK
CANCEL KEYPAD
EXPOSE ERRORATTENTIONLEDS
Figure 2-1 Control Panel
14 AG111334 Rev. 2
Keys
PREVIOUS - Moves you backward within the menu or moves the cursor backward within the current menu item.
ENTER - Enter or exit the menu sub-system by pressing MENU from the ONLINE state.
NEXT - Moves you forward within the menu or moves the cursor forward within the current menu item.
START - Starts exposing the loaded plate. Also, from anywhere in a numeric field, causes the next menu item to be displayed. In the last item of a menu, causes a return to the first item of the menu.
SELECT -Increments the numeric digit under which the cursor is positioned or scrolls through the options available for the current menu item
CANCEL - Cancels a pending “load plate” request, but does not stop a job that is in progress.
STOP - The Emergency stop button. This button will stop all moving parts of the platesetter.
LEDs
.Green LED that indicates the plate is being exposed when it is flashing. Additionally, indicates registration pin contact when loading a plate.Yellow LED indicates there is a condition that requires operator attention. The LCD display indicates what needs to be done.Red LED that indicates a platesetter error condition. The LCD display indicates what the error is.
PREVIOUS
MENU
NEXT
OK
SELECT
CANCEL
EXPOSE
ATTENTION
ERROR
AG111334 Rev. 2 15
Operator MenusThere are three operator menus:
• User Preference Menu (see page 17).
• User Maintenance Menu (see page 22).
• Test Pattern Menu (see page 24).
Menu Selection
Follow these steps to set the parameters in any menu.
Step 1. Press MENU to enter the user menu system.
Step 2. Press SELECT until the sub-menu you want displays on the LCD.
Step 3. Press NEXT to enter the selected sub-menu.
Step 4. Set the parameter to what you want.
Step 5. Press SELECT to change the value.
Step 6. Press NEXT to go to the next parameter until you have completed your selections.
Step 7. Repeat steps 4 and 5 until all changes are made.
Step 8. Press MENU to exit the user menu system.
Figure 2-2 User Menu Structure
ONLINE
PREFERENCES TEST PATTERNS
SELECT
NEXT
USERPREFERENCES
USERMAINTENANCE
TESTPATTERNS
SELECT SELECT
MENU
NEXT NEXT
16 AG111334 Rev. 2
User Preference MenuUNITS OF MEASUREOPTIONS ENGLISH (inches) or METRIC (millime-
ters)
The selected units of measure apply to all numeric measurement values in various menus.
AUDIO ALERTSOPTIONS ENABLED or DISABLED
This menu item allows you to disable or to enable the audible alarms for the following conditions:
Error conditions, Power-up, Image complete
HORIZONTAL MAGNIFICATIONLIMITS 85.00% to 110.00%
Sets the size of the image in the horizontal direction from 85% to 110% of nominal.
Note: The CtServer magnification setting overrides the control panel setting.
VERTICAL MAGNIFICATIONLIMITS 85.00% to 110.00%
Sets the size of the image in the vertical direction from 85% to 110% of nominal.
Note: The CtServer magnification setting overrides the control panel setting.
AG111334 Rev. 2 17
Figure 2-3 User Preferences Menu Map
REGISTRATIONDELAY BEFORE
PINCHING
UNITS OF
AUDIO ALERTS
User Preferences Menu
MEASURE
HORIZONTAL
VERTICAL
IMAGE
MAGNIFICATION
MAGNIFICATION
OFFSET
IGNORE LASERTEMP. ERRORS
PROCESSORSPEED
OVERLAPOUTPUTTING &
IMAGING
USERPREFERENCES
USERMAINTENANCE
SELECT TEST PATTERNSTEST
PATTERNS
ONLINE
SELECT SELECT
MENU
NEXT
ONLY 1 PIN BARIN USE
USE TRANSPORTAS OUTPUT TRAY
USE PLATELINEINTERFACE
AUTOMATICALLYBEGIN IMAGING
AFTER PINCHING
INDEXING ISENABLED
PRE IMAGESETTLE TIME
ONLINE
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT
18 AG111334 Rev. 2
IMAGE OFFSETLIMITS -0.300” to +0.300” (-7.62mm to +7.62mm)
The image may be shifted to the left with a negative (-) value, or to the right with a positive (+) positive value.
ONLY 1 PIN BAR IN USEOPTIONS: YES or NO
“YES” prevents the system from displaying a prompt to verify that the correct pin bar is installed whenever you open an autoloader cover. “NO” permits the system to display the prompt.
IGNORE LASER TEMPERATURE ERRORSOPTIONS YES or NO
If the laser exceeds its target operating temperature an error will be reported. It is recommended that this problem be fixed. However, if critical jobs need to be completed, it is possible to operate the laser at a higher temperature. This operation is enabled by ignoring the laser temperature errors.
Note: Operating the laser at a higher temperature shortens the life of the laser.
OVERLAP OUTPUTTING AND IMAGINGOPTIONS YES or NO
If this option is set “YES,” an operator can begin imaging another plate while the previous plate is feeding into the processor.
PROCESSOR SPEEDLIMITS 9.5” per minute to 77.9”
(241 mm/min. to 1980 mm)
Should be set to match the speed of the online processor.
AG111334 Rev. 2 19
USE TRANSPORT AS AN OUTPUT TRAYOPTIONS: YES or NO
“YES” disables the media transport conveyor and effectively makes the transport function as an output tray. “NO” (the default setting) enables the conveyor to operate and transport plates to the processor.
USE THE PLATELINE INTERFACE
OPTIONS: YES or NO
“YES” enables the plateline interface to halt the platesetter when another device in the plate line is not ready to perform its function. “NO” causes the platesetter to ignore the plateline interface. This feature should be set to “NO” if a plateline interface is not being used.
REGISTRATION DELAY BEFORE PINCHING PLATELIMITS 0.10 seconds to 5.00 seconds
Sets the length of time the system waits to close the pinch rollers after the plate is registered. The default setting is 0.50 seconds.
AUTOMATICALLY BEGIN IMAGING AFTER PINCHINGOPTIONS YES or NO
YES enables the platesetter to automatically image the plate immediately after the pinch rollers close. NO disables the platesetter from doing so.
When NO is selected, you must manually initiate imaging by pressing the OK button.
20 AG111334 Rev. 2
INDEXING IS ENABLEDOPTIONS YES or NO
When YES is selected, the platesetter indexes the input rollers before starting each new image.
When NO is selected, the platesetter does not index the rollers. This improves throughput, but may impact repaeatability and/or registration.
Note: This feature is useful in systems that have an autoloader. If you have a manual load system, leave the feature set for the default (YES) setting.
PRE-IMAGE SETTLE TIMELIMITS 0.50 to 2.50 seconds
The default setting is 2.00 seconds.
Reducing the settle time improves throughput, but may decrease image quality at the leading edge of the plate.
Note: This feature is useful in systems that have an autoloader. If you have a manual load system, leave the feature set for the default (2.00) setting.
AG111334 Rev. 2 21
User Maintenance MenuPROGRAM VERSIONSThis user maintenance option displays version numbers of the installed software and firmware. The versions are displayed as:
CONTROLLER nnnnnn JP0020 n.n JA1135 n
“NEXT” TO CONTINUE
where nnnnnn is the part number of the controller board, JP0020 n.n is the part number and revision level of the controller software, and JA1135 n is the part number and revision level of the controller firmware.
RUN TRANSPORTThis user maintenance option will run the media transport until the STOP button is pressed. This function is used to clean the transport.
RUN MEDIA ROLLERSThis option runs the media rollers until the STOP button is pressed. This function is used to clean the rollers.
DISPLAY ERROR LOGThis user maintenance option presents system faults (up to a maximum of 20 faults) in chronological order. TIME is the elapsed time since the latest power on. SESSION # is the total number of times the system has been turned on. DEVICE NAME identifies the system component that failed. ERROR is an indication of the nature of the fault.
DISPLAY LASER LOGThis option presents status information about the system laser. The information is useful to service personnel, who sometimes request the information over the phone during service calls.
22 AG111334 Rev. 2
Figure 2-4 User Maintenance Menu Map
USERPREFERENCES
User Maintenance Menu
PROGRAM
RUN
VERSIONS
RUN
DISPLAY
MEDIA ROLLERS
ERROR LOG
TRANSPORT
MENU
DISPLAYLASER LOG
USERMAINTENANCE
SELECT TEST PATTERNS
TESTPATTERNS
ONLINE
PREV NEXT
MENU SELECT
OK
CANCEL
EXPOSE ERRORATTENTION
ONLINE
SELECT SELECT
MENU
NEXT
SELECT
SELECT
SELECT
SELECT
SELECT
invoke the displayor exercise the
function.
NEXT
NEXT
NEXT
NEXT
NEXT
NEXT Press to
AG111334 Rev. 2 23
Test Patterns MenuThe test patterns menu is used to select and run one of the several preprogrammed test patterns.
The test patterns menu options are summarized below. Some options are test-pattern specific, which means they may or may not be displayed, depending on which test pattern you select.
TEST PATTERN MODEOPTIONS Enabled or Disabled
This option moves the system in and out of test pattern mode.
TEST PATTERN TYPEOPTIONS List of Test Patterns
Test Patterns are described fully in the system Reference guide and are for the use of qualified technicians only.
NUMBER OF PLATESOPTIONS 1 to 60 plates
Sets the number of plates that will be imaged in the test session.
REVERSE IMAGE POLARITYOPTIONS YES or NO
Reverses the test pattern images. YES will expose the background of the plate. NO will expose the image area.
BAR WIDTHOPTIONS 1 to 999999 Pixels
Specifies the width of the lines in the Bar Test Patterns.
BAR SPACINGOPTIONS 1 to 999999 Pixels
This parameter specifies the width of the spaces between the lines in the Bar Test Patterns.
24 AG111334 Rev. 2
Figure 2-5 Typical Test Pattern Menu Map (Checkerboard selected)
ONLINE
TESTPATTERN
MODE
USERPREFERENCES
USERMAINTENANCE
SELECTTEST
PATTERNSTEST
PATTERNSSELECT SELECT
MENU
NEXT
SELECTNEXT SELECT NEXT
ENABLE DISABLE
TEST PATTERNS
PRESS SELECT TO SCROLLTHROUGH THE SELECTIONOPTIONS. WHEN THE DESIRED O
nly
appl
ies
if “P
late
is
Not
ch R
egis
tere
d”
is s
et to
YE
S.
OPTION APPEARS (FOR EXAMPLE,“CHECKERBOARD”) PRESS NEXT TO SET UP PARAMETERSFOR RUNNING THAT TEST.
ONLINE
NEXT
NOTCH DEPTH
NEXT
PLATE WIDTH
LEVELEXPOSURE
PLATE LENGTH
NEXT
PLATE IS NOTCHREGISTERED
NEXT
VERTICALMAGNIFICATION
NEXT
DISTANCE FROMLEADING EDGE
NEXT
HORIZONTALMAGNIFICATION
NEXT
POLARITYREVERSE IMAGE
NEXT
NEXT
SELECTION OPTIONS
NEXT
OK
RUN CONTINUOUSLY
DROOP (SCOPE)DROOP (MEDIA)
CHECKERBOARD
BARS (HORIZONTAL)BARS (VERTICAL)
GRID
LASER
STEP WEDGE
NEXT
PLATESNUMBER OF
AG111334 Rev. 2 25
IMAGE LENGTHOPTIONS 0.027” to 39.330” or 2 mm to 999 mm
This parameter specifies the length of the test pattern to be recorded.
IMAGE OFFSET (VERTICAL)OPTIONS 0.0000” to 39.330” or 0 mm to 999 mm
This parameter specifies the distance from the leading edge of the plate to the first line of the image.
HORIZONTAL RESOLUTIONBy picking any of the optional values, you set the horizontal resolution to that value. Horizontal Resolution is not displayed if a GRID test pattern is selected.
OPTIONS 1200, 1270, 1800, 2400, 2540, 3048 and 3556 (dpi)
47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0 (dpmm)
Note: Resolution is model dependent. Your options may differ from those listed above. See Table 1 - 1, “FEATURE COM-PARISONS,” on page 2.
VERTICAL RESOLUTIONOPTIONS 1200, 1270, 1800, 2400, 2540, 3048 and
3556 (dpi)
47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0 (dpmm)
By picking any of the optional values, you set the vertical resolution to that value. Vertical Resolution is not displayed if a GRID test pattern is selected.
Note: Resolution is model dependent. Your options may differ from those listed above. See Table 1 - 1, “FEATURE COM-PARISONS,” on page 2.
26 AG111334 Rev. 2
PLATE WIDTHOPTIONS 8.897” to 26.063” or 226.0 mm to
662.0 mm
By picking a value, you set the plate width for test patterns.
Plate width is model dependent. Your options may differ from those listed above. See Table 1 - 1, “Feature Comparison, MAKO System 4 and 4x Platesetters,” on page 2.
Plate width is model dependent. Your options may differ from those listed above. See Table 1 - 1, “FEATURE COMPARISONS,” on page 2
PLATE LENGTHOPTIONS 9.842” to 37.873” or 250.0 mm to
961.9 mm
By picking a value, you set the plate length for test patterns.
Plate length is model dependent. Your options may differ from those listed above. See Table 1 - 1, “Feature Comparison, MAKO System 4 and 4x Platesetters,” on page 2.
Plate length is model dependent. Your options may differ from those listed above. See Table 1 - 1, “Feature Comparison, MAKO System 4 and 4x Platesetters,” on page 2
PLATE IS NOTCH REGISTEREDOPTIONS YES or NO
By picking a selection, you set the alignment to be used for test patterns. Punched plates are generally notch registered as opposed to edge registered.
AG111334 Rev. 2 27
NOTCH DEPTHOPTIONS 0.000” to 1.000” or 00.0 mm to 25.4
mm
By picking a value, you set the notch depth for test patterns.
DISTANCE FROM NOTCH TO LEADING EDGEOPTIONS 1.665” to 37.873” or 42.3 mm to 961.9
mm
This options specifies the distance from the leading edge of the plate to the center of the notch that is closest to the leading edge. This parameter is only for notch-registered plates.
EXPOSURE LEVELLIMITS 000 to 255
This menu entry sets the exposure level at the media. The higher the number, the higher the exposure.
HORIZONTAL MAGNIFICATIONLIMITS 85.00% to 110.00%
Sets the size of the image in the horizontal direction from 85% to 110% of nominal.
VERTICAL MAGNIFICATIONLIMITS 85.00% to 110.00%
Sets the size of the image in the vertical direction from 85% to 110% of nominal.
28 AG111334 Rev. 2
Equipment Configuration DisplaysThese displays summarize the equipment configuration of the system. If you call for service, your service provider may ask you to read the content of the displays to him over the phone, before he goes to your site to service your system.
To view the displays:
Step 1. Place the system in ONLINE mode.Step 2. Press the Select key. The first display appears.
Step 3. Press the Select key again. The second display appears.
Step 4. Convey the information on the LCD to your service provider.
Step 5. Press the select key to clear the display and return to ONLINE mode
Figure 2-6 Configuration Displays
SELECT
SYSTEMCONFIGURATION
THE SCREENS DISPLAY THE FOLLOWING INFORMATION ABOUT YOUR SYSTEM:
------------------ DISPLAY 1 -----------------
MACHINE TYPE*
CONTROLLER P/N / MACHINE ID #
FIRMWARE
LASER POWER/FILM SENSITIVITY/OPTICAL EFFICIENCY
---------------- DISPLAY 2 ---------------
OUTPUT TYPE
SPINNER MOTOR-------------------------------------------------------------------
ONLINE
SELECT
SELECT
DISPLAY 1
SYSTEMCONFIGURATION
DISPLAY 2
AG111334 Rev. 2 29
Display MessagesDuring operation, the system displays status messages about the condition of the system and the progress of any jobs in process. The status messages appear on the control display. PREPARING TO EXPOSE - The system is starting the spinner and moving the plate to the recording start position.EXPOSING IMAGE - The system is now recording an image.EJECTING PLATE - Exposing is complete and the plate is being ejected onto the plate transport.MOVING TO PROCESSOR - Plate has been ejected from the rollers and is moving to the processor.FEEDING PROCESSOR - Plate is on the transport and the leading edge of the plate is moving into the processor.EJECTING PLATE - Exposing is complete and the plate is being ejected onto the plate transport.ONLINE - The normal operating mode for the systemSTARTING SPINNER - This message is accompanied by a progress bar when preparing to start an image and the spinner motor is TEST PATTERNS - Test Patterns mode has been selected in the Test Patterns Menu and the system is ready to produce a test pattern. This mode of operation should be used by qualified service technicians only.INITIALIZING - The system is performing initialization functions prior to going online.
Note: On a MAKO System 4, if the Pinch Roller bar is down, you will be prompted to raise it during initialization.
WAITING FOR LASER - The system is waiting for the laser to reach its operating temperature.
30 AG111334 Rev. 2
Running a Step Wedge Test
About the Step Wedge Test
The step wedge test is used to calibrate the exposure setting to match the plate and the processor chemistry. The test applies to photopolymer plates only.
The test involves taping a step-wedge test strip on the plate, exposing the plate, and evaluating the resultant test image as explained below.
Note: ECRM strongly recommends new processor chemistry be used to process step-wedge test plates.
The figure below shows a step-wedge test strip. It happens to have 15 steps. Some test strips have fewer than 15 steps, whereas others have more.
On any given test strip, the first step is virtually clear, the last step is virtually black, and steps in between are of varying density, with each step being darker than the preceding (lower-numbered) step.
Figure 2-7 Example Step-Wedge Test Strip
When the test strip is taped over the plate, “clear” step 1 allows virtually all of the energy in the imaging beam to hit the plate, step 2 slightly less energy, step 3 still less energy, etc.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
AG111334 Rev. 2 31
On a typical test plate, the lower-numbered wedge steps are completely imaged (very dark), the higher-numbered steps are barely imaged (very light/clear), and one or two transition steps between the dark and light areas are partially imaged.
Figure 2-8 Typical Step-Wedge Test Plate Image
The distribution of dark steps, transition steps, and light step varies depending on the platesetter’s exposure setting, the plate type being used, and the state of the processor chemistry.
Prepare a plate for the test
Step 1. Obtain a step wedge test strip.
Note: ECRM recommends using a Fuji 15-step “T” step wedge test strip (ECRM PH0388) on Fuji plates, and a Stouffer 21-step wedge (ECRM PH0389) on all other plates.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4
56 7 8 9 10 11 12 13 14 1575
32 AG111334 Rev. 2
Step 2. Center the test strip on the plate 6 inches (15.2 cm) back from the leading edge, as shown below. Be sure to use two pieces of tape. Make sure the emulsion side of the step wedge faces the emulsion side of the plate.
Figure 2-9 Step Wedge Test Strip Placement
Run the Step Wedge Test Pattern
Step 1. At the control panel, press MENU and then repeatedly press SELECT until the “Test Patterns” Menu displays.
Step 2. Press NEXT, and then press SELECT to Enable.
Step 3. Press NEXT, and then repeatedly press SELECT until the Step Wedge pattern displays. Then, press NEXT again.
Step 4. Set Horizontal resolution to the required resolution.
Step 5. Set Vertical resolution to the required resolution.
Step 6. Set Exposure to the value you wish to expose the wedge (range is 0-255.)
Step 7. Set plate source to Manual.
STEP WEDGE
Centerline of Plate6 inches
TAPE
TAPE
Leading Edge of Plate
15.2 cm
TEST STRIP
AG111334 Rev. 2 33
Step 8. Set Plate Thickness to the plate thickness being used.
Step 9. Set Plate Width to the plate width being used.
Step 10. Set Plate Length to the plate length being used.
Step 11. Set Magnification Horizontal to the magnification being used (nor-mally 100%).
Step 12. Set Magnification Vertical to the magnification being used (nor-mally 100%).
Step 13. Select MENU.
Step 14. Press the SELECT key to begin exposing the test plate.
The system exposes 100% of the first 8 inches of the plate at the exposure setting selected. After exposure, the plate moves onto the transport belt and advances until the leading edge of the plate is detected by the transport exit sensor. The transport then stops, the warning light on the top cover flashes, and a prompt to open the transport cover and remove the step wedge displays on the control panel.
Note: Note: In step wedge test pattern mode, the machine will not beep or report cover interlock open messages.
Step 15. On the front panel, press OK. The transport feeds the plate into the processor.
Step 16. Process the plate.
Step 17. Evaluate the output.
34 AG111334 Rev. 2
Evaluating the Output
Step 1. Refer to the sidebar at the right. It defines terms we will use later.
Step 2. Examine your test plate to see where the Solid, Tail, and Clear steps are located.
Step 3. Refer to the table below for exposure step wedge values for several popular plate types. The values shown in the table are for an ideal testing environ-ment. Plate lot, plate age, processing conditions, and processor chemistry can have a dramatic effect on step wedge results. Always check these factors if your step wedge test results signifi-cantly differ from those shown in the table.
Plate Manufacturer
Plate Product Name
Step WedgeTest Strip
Step Wedge Values when Exposure is Correct
Fuji LP-NV PH0388 Solid 3, Scum 4 or 5
Lastra LV-2 PH0389 Solid Step 3 to 4+, Tail 5 and up
KPG Violet Plate PH0389 Light tail 5
Agfa N91V PH0389 Solid 3, Scum 5
3
4
5
6
23
4
5
6
Solid
Tail*
Clear
No brush marks appear. Step # may be visible.
Approximately 50% exposure of area. Brush marks visible.
Some minimal ghosting may appear.
STEP WEDGE SCALE
* Sometimes called Ghost or Scum, Tail steps exhibit only partial exposure of the plate.
Figure 2-10
AG111334 Rev. 2 35
Step 4. Example Figure 2-11 below shows how Fuji LP-NV test plates look for different exposure settings. Use the figure as a guide for evaluating your test output. If necessary, increase/decrease the platesetter’s exposure setting and then run another wedge test.
Figure 2-11
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
EXPOSURE SETTING TOO LOW
EXPOSURE SETTING TOO HIGH
CORRECT EXPOSURE SETTING
C
A
B
36 AG111334 Rev. 2
3Media Handling Media Specifications
Configurations •Prepunched Press Grooves or•Edge Register
Media Thicknesses• 5.5 mil (0.14mm)• 6 mil (0.15 mm)• 8 mil (0.20mm) • 10 mil (0.25mm)• 12 mil (0.30mm)
Plate Sizes
Safelight RequirementThe platesetter is designed to be operated in a safelight environment. All media handling must be done under safelight conditions. Safe working time varies with manufacturer. See the plate manufacturer’s specification for safelight recommendations.
L = LengthW = Width
MEDIA
Figure 3-1 Media Orientation
MAKO 2 CTP
SYSTEM PLATE SIZE (MM)Maximum
Edge RegisterMaximum
Notch RegisterMinimum
Edge Register
MAKO 4 CTP
MAKO 4X CTP
MAKO NEWS CTP
560 mm (W) x 670 mm (L)
615 mm (W) x 745 mm (L)
635 mm (W) x 960 mm (L)
635 mm (W) x 960 mm (L)
560 mm (W) x 670 mm (L)
615 mm (W) x 745 mm (L)
635 mm (W) x 960 mm (L)
660 mm (W) x 960 mm (L)228 mm (W) x 252 mm (L)
228 mm (W) x 252 mm (L)228 mm (W) x 252 mm (L)
228 mm (W) x 252 mm (L)MAKO 2X CTP 560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 228 mm (W) x 252 mm (L)
AG111334 Rev. 2 37
Installing and Removing the Pin BarThe pin bar provides alignment points that insure accurate plate registration. There are two types of pin bars: notch-registered and edge-registered. Notch-registered pin bars are for registering plates that are punched with a specific notch pattern. The edge-registered pin bar is used to edge register a plate. Typically, notch registration provides more consistent registration than edge registration.
Note: The platesetter does not “know” which pin bar is loaded. It is up to you to make sure the pin bar is appropriate for the plate that is being used.
The pin bar is located in a channel on the left side of the input tray.
Figure 3-2 Pin Bar Location
PIN BAR
CHANNEL
INPUT TRAY
Note: MAKO 2x, MAKO 4x and MAKO NEWS models do not have a pinch roller bar.
PINCH ROLLERBAR
38 AG111334 Rev. 2
Figure 3-3 shows the main parts of the pin bar. The alignment pin helps keep the pin bar in proper alignment with the rest of the media handling system. The latch at the other end of the pin bar locks the bar in place in the channel.
Figure 3-3 Pin Bar
Installing a Pin Bar
Step 1. If necessary, remove the existing pin bar as explained in “Removing a Pin Bar” on page 41.
Step 2. Hold the new pin bar with the latch end in your left hand and the alignment pin end in your right hand.
Step 3. Look for the small hook at the front of the channel (see Figure 3-4 on Page 40).
ALIGNMENT PIN
REGISTRATION PINS
LATCH
AG111334 Rev. 2 39
Figure 3-4 Alignment Pin Hook
Step 4. Position the pin bar over the channel with the alignment-pin end at the front of the channel and the latch at the back of the channel.
Step 5. Holding the pin bar at a 45-degree angle, snap the pin bar align-ment pin into the hook as shown in Figure 3-5.
Step 6. Press down on the alignment pin so that it stays in the hook; then, lower the other end the pin bar into the channel until the latch snaps and locks the bar in place.
HOOK
FRONT OF
CHANNEL
40 AG111334 Rev. 2
Step 7. Firmly press the center of the pin bar down to insure it is properly seated.
Figure 3-5 Setting the Alignment Pin in the Hook
Removing a Pin Bar
Step 1. Push the pin bar latch forward to disengage the latch.
Step 2. Lift the pin bar up by the latch until the bar is at about a 45 degree angle.
Step 3. At the front of the pin bar, disengage the alignment pin from the hook in the channel.
Step 4. Carefully remove the pin bar and store it in a safe place.
ALIGNMENT
PIN BAR
CHANNEL
PIN
HOOK
AG111334 Rev. 2 41
Loading MediaCtServer will request a pin bar and plate to be loaded, and the platesetter will prompt you to load the plate. One of the following prompts appears on the control panel LCD:
LOAD A PLATE<plate name><bar name>
This message indicates that the next plate to be imaged is the same as the preceding plate. It is a prompt for you to load the same kind of plate that was just imaged.
LOAD A NEW PLATE<plate name><bar name>
This message indicates that the next plate to be imaged is different than previous plate, but that it uses the same pin bar. It is a prompt for you to load the new (different) type plate.
VERIFY BAR AND LOAD<plate name><bar name>
The meaning of this message depends on when it appears during the CtServer (host computer) session. When the session is first opened, it is a prompt for you to ensure that the correct pin bar is installed before loading the first plate, and then to load the plate. Subsequently in the session, the message indicates that the next plate to be imaged is different than the preceding plate AND requires a different pin bar. Thus, it is a prompt for you to change the pin bar and load the new (different) plate.The technique used for loading plates is a key in achieving good plate registration. Always handle and position the plate gently and carefully. Thin plates are especially susceptible to dings and dents.
42 AG111334 Rev. 2
Figure 3-6 External View of the System
POWER SWITCH
CONTROL PANEL
PINCH ROLLER BAR*
INPUT TRAYFAN FILTER
PEDESTAL
PIN BAR
(Not present in MAKO 2x, MAKO 4x
* MAKO 4x and MAKO NEWS models have an automatic pinch mechanism.
MEDIA TRANSPORT
BACK FRONT
and MAKO NEWS models)
AG111334 Rev. 2 43
Loading Edge-registered Plates in a MAKO 2 or MAKO 4
Step 1. Face the front of the platesetter.
Step 2. Raise the pinch roller bar to open the pinch roll-ers. Be sure the pinch roller is fully raised. If it is not, the green Expose LED on the control panel will not light.
Step 3. Verify the requested pin bar is loaded. If it is not, change the pin bar.
Step 4. Place the requested plate on the input tray. Step 5. Push the plate to the left (Figure 3-7, “A”) so that the edge of the
plate contacts the registration pins in the pin bar.
Figure 3-7 Loading Edge-registered Plates
Step 6. Push the plate forward into the platesetter (Figure 3-7, “B”) until you feel it make contact with a third registration pin that is inside the platesetter.
Note: For instructions for loading an edge-registered plate in a system with an automatic pinch mechanism, refer to“Loading Edge-registered Plates in a MAKO 2x, MAKO 4x or MAKO NEWS System” on page 49.
PLATE
PIN BAR
EDGE
REGISTRATION
PINCH ROLLERS
OF PLATE
PIN
AB
REGISTRATIONPIN
44 AG111334 Rev. 2
Step 7. Gently adjust the position of the plate as needed to get the green Expose LED to come on and stay on. This shows the plate is maintaining contact with all 3 registration pins (the 2 on the pin bar, plus the 1 inside the platesetter).
If the LED goes out, you have lost pin contact. Move the plate out and to the right slightly, and then back in and to the left until the green LED stays on. Be careful to not apply so much pres-sure to the plate that the registration pins dent the plate. Use one finger/thumb to apply minimal pressure to the center of the plate.
Note: If the green LED is not stay-ing illuminated, the pin bar may not be fully seated. Remove and reinstall the pin bar, following the instruc-tions above.
Step 8. Holding the plate in position, lower the pinch roller bar. The green light will remain on if pin contact has been main-tained and the platesetter will prompt for the OK button to be pressed to start imaging.
Note: If the green LED does not stay illuminated, open the pinch roller bar and go back to Step 5.
Step 9. Press the OK button. Imaging begins.
CAUTION - Never raise the pinch roller bar while a plate is being exposed. Doing so will cause the plate to jam inside the platesetter. For details, refer to ““Clearing Misfeeds, Manual Pinch Mechanism” on page 58”.
Step 10. After the plate is imaged, it is automatically transported from the platesetter to the on-line processor via the media transport.
PREV NEXT
MENU SELECT
OK
CANCEL
EXPOSE ERRORATTENTION
GREEN LED
OK
Figure 3-8
AG111334 Rev. 2 45
Loading Notch-registered Plates in a MAKO 2 or MAKO 4
Step 1. Face the input tray.
Step 2. Raise the pinch roller bar to open the pinch roll-ers. Be sure the pinch roller is fully raised. If it is not, the green Expose LED will not light.
Step 3. Verify the requested pin bar is loaded. If it is not, change the pin bar.
Step 4. Place the requested plate on the input tray.
Step 5. Position the plate so that both notches in the plate fully engage the two registration pins on the pin bar (see Figure 3-9 on Page 47).
Note: For instructions for loading an edge-registered plate in a system with an automatic pinch mechanism, refer to“Loading Notch-registered Plates in a MAKO 2x, MAKO 4x, or MAKO NEWS System” on page 51.
46 AG111334 Rev. 2
Figure 3-9 Loading Notch-registered Plates.
Step 6. Watch for the green Expose LED to come on and stay on. This shows the plate is maintaining contact with the pins. If the LED goes out, you have lost pin contact. Move the plate slightly away from the registration pins and then back against them again until the green LED stays on. Be careful to not apply so much pressure to the plate that the registration pins dent the plate. Use one finger/thumb to apply minimal pressure to the center of the plate while lifting the plate slightly.
Note: If the green LED is not staying illuminated, the pin bar may not be fully seated. Remove and reinstall the pin bar, fol-lowing the instructions above.
PLATE
PIN BAR
REGISTRATION PIN
PINCH ROLLERS
REGISTRATION PIN
NOTCH
PIN BAR
AG111334 Rev. 2 47
Step 7. Holding the plate in position, lower the pinch roller bar. The green light will remain on if pin contact has been maintained and the platesetter will prompt for the OK button to be pressed to start imaging.
Note: If the green LED does not stay illuminated, open the pinch roller bar and go back to Step 5.
Step 8. Press the OK button. The plate will be backed up to properly posi-tion the leading edge for exposing.
Step 9. After the plate is imaged, it will automatically be transported out of the platesetter and into the on-line processor.
48 AG111334 Rev. 2
Loading Edge-registered Plates in a MAKO 2x, MAKO 4x or MAKO NEWS System
Step 1. Face the front of the platesetter.
Step 2. Verify the requested pin bar is loaded. If not, change the pin bar.
Step 3. Place the requested plate on the input tray.
Note: Always handle and position the plate gently and carefully. Thin plates are especially susceptible to dings and dents.
Step 4. Push the plate to the left so that the edge of the plate contacts the registration pins in the pin bar (see “A” in Figure 3-10).
Figure 3-10 Loading Edge-registered Plates
Note: For instructions for loading an edge-registered plate in a system with a manually operated pinch mechanism, refer to“Loading Edge-registered Plates in a MAKO 2 or MAKO 4” on page 44.
PLATE
PIN BAR
EDGE OF
REGISTRATION
PINCH ROLLERS“THIRD”
REGISTRATIONPIN
A
BPIN
PLATE
AG111334 Rev. 2 49
Step 5. Push the plate forward (“B” in Figure 3-10) until it comes into con-tact with a third registration pin that is inside the platesetter.
Step 6. Gently adjust the position of the plate until the green “Expose” LED stops blinking and stays on steady. (Steady on indicates the plate is making contact with all the registration pins).
Step 7. The platesetter automatically lowers the pinch rollers.
Note: The platesetter will not lower the pinch rollers until elec-tronics sensors report that the plate is making good con-tact with all the registration pins.
If the pin bar isn’t properly seated in its mount, the sensors may not operate correctly and the platesetter may not close the pinch rollers. If you load a plate that it is making good contact with the registration pins but the pinch roll-ers don’t close, try re-seating the pin bar.
After the pinch rollers close, the platesetter does either of the following, depending on the setting of the Automatically Begin Imaging After Pinching menu option:
•automatically begins imaging the plate,
or
• displays a “PRESS OK TO BEGIN” prompt on the control panel display.
Step 8. If the prompt appears, press the OK button.
Step 9. After the plate is imaged, it is automatically transported to the on-line processor via the media transport.
See “User PreferencesMenu” on page 13. for moreabout the AutomaticallyBegin Imaging AfterPinching menu option.
50 AG111334 Rev. 2
Loading Notch-registered Plates in a MAKO 2x, MAKO 4x, or MAKO NEWS System
Step 1. Face the input tray.
Step 2. Verify the requested pin bar is loaded. If it is not, change the pin bar.
Step 3. Place the requested plate on the input tray.
Step 4. Position the plate so that both notches in the plate fully engage the two registration pins on the pin bar (see Figure 3-11).
Figure 3-11 Loading Notch-registered Plates.
Note: For instructions for loading a notch-registered plate in a system with a manually operated pinch mechanism, refer to“Loading Notch-registered Plates in a MAKO 2 or MAKO 4” on page 46.
PLATE
PIN BAR
REGISTRATION PIN
PINCH ROLLERS
REGISTRATION PIN
NOTCH
PIN BAR
AG111334 Rev. 2 51
Step 5. Gently adjust the position of the plate until the green “Expose” LED stops blinking and stays on steady. (“Steady” on indicates the plate is making contact with all the registration pins).
Step 6. The platesetter automatically lowers the pinch rollers.
Note: The platesetter will not lower the pinch rollers until elec-tronics sensors report that the plate is making good con-tact with all the registration pins.
If the pin bar isn’t properly seated in its mount, the sensors may not operate correctly and the platesetter may not close the pinch rollers. If you load a plate that it is making good contact with the registration pins but the pinch roll-ers don’t close, try re-seating the pin bar.
After the pinch rollers close, the platesetter does either of the following, depending on the setting of the Automatically Begin Imaging After Pinching menu option:
• automatically begins imaging the plate, or
• displays a “PRESS OK TO BEGIN” prompt on the control panel display.
Step 7. If the prompt appears, press the OK button.
Step 8. After the plate is imaged, it is automatically transported to the on-line processor via the media transport.
See “User PreferencesMenu” on page 13. for moreabout the AutomaticallyBegin Imaging AfterPinching menu option.
52 AG111334 Rev. 2
4Maintenance and TroubleshootingIntroduction
This chapter discusses:
• General Maintenance
• Moving the System
General MaintenanceThis chapter explains how to keep the system in clean, working order. Remember to shut the power off to the machine prior to performing any internal maintenance procedures. Use only the recommended cleaner. Make sure the cleaning supplies are free of lint and dirt.
AG111334 Rev.2 53
Figure 4-1 System Details
Cleaning the System
Clean the outside of the system and the pin bar with any mild detergent in clean water using a soft, cotton cloth. Don’t use abrasive cleansers or chemical cleansers.
Cleaning the Fan Filters
Two filtered fans run at all times to maintain an air flow inside the machine. Both fans use a 3.6” x 3.6” aluminum filter like the one shown in the next figure. (ECRM P/N FF0087).
POWER SWITCH
CONTROL PANEL
PINCH ROLLER BAR
MEDIA TRANSPORT
INPUT TRAY
PEDESTAL
PIN BAR
POWER CORD
(NOT PRESENT IN MAKO 2X, MAKO 4X
BACK FRONT
AND MAKO NEWS)
OUTPUT SENSOR
INPUT SENSOR(NOT PRESENT IN MAKO 2 AND MAKO 4)
FAN FILTER
54 AG111334 Rev.2
The filters can become clogged with dust and other debris if it is not cleaned regularly. A clogged filter can result in the loss of internal pressure and increase the possibility of a system malfunction. Clean the filters whenever they show signs of contamination with dust or other debrisHere’s how to remove and replace a filter:
Step 1. Turn the power switch off.
Step 2. From inside the pedestal, reach up and under the machine where the on/off switch is located. See Figure 4-3.
Step 3. Place your fingers on the filter. It has a corrugated feel.
Step 4. Gently push the filter toward the outside of the machine until the filter protrudes from the slot shown below.
Figure 4-3 Fan Filter Removal
Figure 4-2
FAN FILTER SLOT
ON/OFF SWITCH
PEDESTAL
AG111334 Rev.2 55
Step 5. Pull the filter out of its slot.
Step 6. Wash the filter in mild, soapy water, rinse in clean water and dry.
Step 7. Place the filter back into the slot.
Step 8. Push the filter, from the outside, until it is completely in the machine.
Step 9. From inside the pedestal, gently push the filter to the middle of the machine until it is fully seated in the holder.
Step 10. Repeat steps 1 through 10 above for the other filter, which is located on the opposite side of the system.
Cleaning the Front Drive Roller
Cleaning the roller will cut down on the contaminants running through the media system. Dirty rollers can cause contamination of the media.
Step 1. If the system has a pinch roller bar, raise it to “open” position.
Step 2. Use the User Maintenance Menu to run the media rollers.
Step 3. Sparingly apply “Fantastik” (ECRM HB2456) to a clean, lint-free wipe.
Step 4. As the rollers turn, gently wipe both the front and back rollers with the cloth, being careful to not ‘catch’ the cloth in the rollers. Do not touch the rollers with bare hands. The oils and dirt will con-taminate the rollers.
Step 5. After wiping with “Fantastik,” sparingly apply isopropyl alcohol to a clean, lint-free wipe.
Step 6. As the rollers turn, gently wipe both the front and back rollers with the cloth, being careful to not ‘catch’ the cloth in the rollers. Do not touch the rollers with bare hands. The oils and dirt will con-
56 AG111334 Rev.2
taminate the rollers.
Step 7. If water fails to remove the gum, use ECRM PH0046 roller cleaner. (Do NOT use alcohol or a general purpose cleaner to clean the rollers.)
Step 8. Exit the User Maintenance Menu.
Cleaning the Back Drive Roller
The rear media roller is not accessible to an operator. The next time you have the system serviced, ask your service provider to clean the rear roller.
Cleaning the Pinch Rollers
The next time you have the system serviced, ask your service provider to clean the pinch rollers.
Cleaning the Input Sensor
Systems with an automatic pinch mechanism have an input sensorlocated beneath the input tray (see Figure 4-1).
Clean the sensor by gently rubbing the sensor with a cotton tip swabmoistened with isopropyl alcohol to remove any debris buildup.
Cleaning the Media Transport Output Sensor
Step 1. Using a cotton tip swab moistened with isopropyl alcohol, gently rub the output sensor (see Figure 4-1) to remove any debris buildup.
Cleaning the Media Transport Belts
Step 1. Use the User Maintenance Menu to run the transport.
Step 2. Using a lint-free cloth moistened with “Fantastik” (ECRM
AG111334 Rev.2 57
HB2456), remove debris from the belt (see Figure 4-1).
Step 3. Using a second lint-free cloth moistened with alcohol, rub down the belt.
Clearing Misfeeds, Manual Pinch MechanismTwo methods for clearing a misfeed are presented below. Use Method 1 if you are using a notch-registered pin bar in a system with a manual pinch mechanism. Otherwise, use Method 2.
Method 1 (for System 4 models only)
Step 1. Lift the pinch roller bar to open the roller.
Step 2. Carefully pull the jammed media out of the rollers.
Step 3. Press the OK button on the control panel.
Step 4. Resume normal operation.
Method 2When an edge-registered pin bar is used, a third “internal” registration pin is activated. The location of this pin (which you can feel but not see when you load a plate) is shown below in Figure 4-4. The pin moves up into the media path when the pinch mechanism is raised, and it drops below the media path when the mechanism is lowered.
58 AG111334 Rev.2
Figure 4-4 Internal Registration Pin
During imaging, the registration pin is below the plate’s path of travel.If a misfeed or a power failure happens to occur and the plate gets “hung up” in the machine with a manual pinch mechanism, you are advised not to raise the pinch roller bar. Doing so will raise the registration pin. If the plate happens to be positioned over the registration pin (Figure 4-5 View B), when the pin comes up and it will bend or dent the plate.
PIN BAR
FRONT PINCH ROLLER
REARPINCH ROLLER
REGISTRATION PIN
REGISTRATION PIN
REGISTRATION PIN
INTERNAL
PLATE
NOTE
The Internal Registration Pin goes up when the Pinch Roller Bar is raised and goes down when the Pinch Roller Bar is lowered.
AG111334 Rev.2 59
Figure 4-5 Plate Positions over the Registration Pin
To insure against this happening, use the following procedure to remove the plate:
Step 1. Do not raise the pinch roller bar or power off the machine.
Step 2. Use the control panel PREV and NEXT buttons as follows to extract the plate:
• Press the PREV button to effect a movement of the plate toward the front of the machine, and then press the button again to stop the movement.
• Press the NEXT button to effect a movement of the plate toward the back of the machine, and then press the button again to stop the movement.
Step 3. Exercise the PREV and NEXT buttons as required until the plate out all the way of the machine.
REGISTRATIONINTERNAL
PIN PLATE PLATE
VIEW A VIEW BPlate not over the pin Plate over the pin
60 AG111334 Rev.2
Step 4. Press the OK button. This turns off the blinking error light and clears the the error message from the display.
Step 5. Resume normal operation.
Moving the SystemWhen installing or moving the system, you must level the system at its new location as explained below. See Figure 4-6 for the location of the leveling feet in the pedestal.
Step 1. Unplug the power cable from the (wall) outlet. Leaving one end of the cable plugged into the platesetter, gently coil the power cable and store it on the shelf in the pedestal.
Step 2. Disconnect the USB cable from the PC attached to the Mako CTP. Leaving the USB cable connected to the platesetter, gently coil the power cable and store it on the shelf in the pedestal.
Figure 4-6 Levelling Feet Location
Step 3. Retract all four levelling feet so the system rides on its wheels and
LEVELING FEET
AG111334 Rev.2 61
place the system in its new location.
Step 4. Turn all four levelling feet of the platesetter down until they just touch the floor.
Step 5. Continue to turn leveling feet until the system is level, front to back and side to side.
62 AG111334 Rev.2
AAUDIO ALERTS menu item 17AUTOMATICALLY BEGIN IMAGING AFTER
PINCHING menu item 20
BBAR SPACING menu item 24BAR WIDTH menu item 24
CCANCEL key 15Cleaning 57
back media rollers 57fan filters 54front media rollers 56media transport belt 57media transport output sensor 57system exterior 54
Clearing misfeeds 58Control panel 6Controller board, part number 22Controller ID 29CtServer software
functions of, 3overriding control panel settings, 4user’s guide, 4
DDISPLAY ERROR LOG menu item 22DISPLAY LASER LOG menu item 22Display messages 30DISTANCE FROM NOTCH TO LEADING EDGE
menu item 28
EENTER key 15Environmental specifications 8Equipment configuration
displays 29EXPOSURE LEVEL menu item 28Exposure, setting 28, 31
FFan filters 54
avoid grasping, 7location of, 7removing 55replacing 56
Firmware, version of 22
HHeat, see System specificationsHORIZONTAL MAGNIFICATION menu item 17,
28HORIZONTAL RESOLUTION menu item 26
IIdentification label, location of 11IGNORE LASER TEMPERATURE ERRORS
menu item 19IMAGE LENGTH menu item 26IMAGE OFFSET (VERTICAL) menu item 26IMAGE OFFSET menu item 19, 20, 21INDEXING IS ENABLED menu item 21Input tray 6
JJams, see Clearing misfeeds
Ll 44Laser
classifiication, 9power of, 29safety concerns, 9warning, 9
LEDsgreen 15
does not light, 44does not stay on, 45
red 15yellow 15
Loading plates see Plate (loading)
MMagnification 17MAKO CTP series
systems included in, 1Media transport
disabling operation of, 20function of, 7
Menusaccessing, 14setting parameters in, 16Test Patterns Menu 24User Maintenance Menu 22User Preference Menu 17
Models, differences between 1Moving the system 61
NNEXT key 15NOTCH DEPTH menu item 28NUMBER OF PLATES menu item 24
OONLY 1 PIN BAR IN USE menu item 19OVERLAP OUTPUTTING AND IMAGING menu
item 19
PParameter settings
CtServer vs. control panel, 4Parameters, setting 16Pedestal 7Pin bar
ensuring the correct one is used, 38function of, 5installing a, 38not seated correctly 47ordering an additional, 6types of, 6, 38
Pinch roller barguidelines for using, 6purpose of, 6
Pinch rollersfail to automatically close (System 4x) 52function of, 6
Plateloading a notch-registered plate
in MAKO 4x or MAKONEWS 51
in the MAKO 2 or MAKO 4 46loading an edge-registered plate
in MAKO 4x or MAKONEWS 49
in the MAKO 2 or MAKO 4 44sizes 37thicknesses 37
PLATE IN NOTCH REGISTERED menu item 27PLATE LENGTH menu item 27PLATE WIDTH menu item 27Power conditioner
functions of, 4required use of, 4
Power cord receptacle 5Power switch
function of, 5location of, 5
PRE-IMAGE SETTLE TIME menu item 21PROCESSOR SPEED menu item 19PROGRAM VERSION menu item 22
RREGISTRATION DELAY BEFORE PINCHING
PLATE menu item 20Registration pins
operation of the "hidden" pin 58the third "hidden" pin 50the third "hidden" pin, 58
Regulatory information 10REVERSE IMAGE POLARITY menu item 24RUN MEDIA ROLLERS menu item 22RUN TRANSPORT menu item 22
SSafelight requirement 8, 37SELECT key 15Sending a job 13Shutting down the system 14Specifications, see System specificationsSpinner motor 29START key 15Starting the system 13Step wedge test 31
purpose of, 31test strip, 32
STOP key 15System components
diagram of, 3list of, 3
System specificationsac power, 8heat dissipation, 8humidity, 8temperature, 8
TTEST PATTERN MODE menu item 24TEST PATTERN TYPE menu item 24TEST PATTERNS menu 24TEST PATTERNS menu item 24
UUNITS OF MEASURE menu item 17USE THE PLATELINE INTERFACE menu
item 20USE TRANSPORT AS AN OUTPUT TRAY menu
item 20USER MAINTENANCE menu 22
USER PREFERENCE menu 17
VVERTICAL MAGNIFICATION menu item 17, 28VERTICAL RESOLUTION menu item 26
WWAITING FOR LASER message 30Warm-up period 5, 13Warranty issues 4Workstation
function of, 3operating instructions for, 3
NOTES