Operator Guide

MAKO 2 CTP, MAKO 2x CTP, MAKO 4 CTP, MAKO 4x CTP, and MAKO NEWS CTP

AO111334 Revision 2

Operator Guide
MAKO 2 CTP, MAKO 2x CTP, MAKO 4 CTP, MAKO 4x CTP and MAKO NEWS CTP
copyright ECRM Incorporated 2008 Additional copies of this guide may be obtained by writing or calling:

ECRM Order Processing

554 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 of ECRM. It cannot be reproduced, in whole or in part, without the express written consent of ECRM. The information is believed to be accurate as of the publication date, but it is subject to change without notice due to continuing product development. ECRM and MAKO are trademarks of ECRM Imaging Systems. Other brand and product names are trademarks or registered trademarks of their respective owners.

Table of Contents
Table of Contents iii Preface v
Scope of this Guide v Organization v Terms and Conventions vi

System Overview 1
The MAKO CTP Series 1 Functional Overview 1 System Components 3 Main Parts of the Platesetter 5 System Requirements 8 Laser Safety 9 Regulatory Information 10

System Operation 13
Introduction 13 Starting Up the System 13 Shutting Down the System 14 Using the Control Panel 14 Operator Menus 16 User Preference Menu 17 User Maintenance Menu 22 Test Patterns Menu 24 Equipment Configuration Displays 29 Display Messages 30 Running a Step Wedge Test 31

Media Handling 37
Media Specifications 37 Safelight Requirement 37 Installing and Removing the Pin Bar 38 Loading Media 42

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Maintenance and Troubleshooting 53

Introduction 53 General Maintenance 53 Clearing Misfeeds, Manual Pinch Mechanism 58 Moving the System 61

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Preface
Scope of this Guide
This guide explains how to operate and maintain MAKO CTP series platesetters. The guide describes all aspects of operating a system. All platesetters in the series use a Class Four laser. This guide contains important safety information and regulatory information about the laser. You should read this information thoroughly before operating the system or performing the procedures described in this guide. This guide assumes the system is already properly installed and plugged into the AC mains, and that the system has been calibrated and tested for proper operation and acceptable output.

Organization
Chapter 1: System Overview
This chapter presents a system overview. It includes system operating requirements and information about laser safety.

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.

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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 Italic typeface Bold typeface Bold sans-serif typeface Note: IMPORTANT Is an instruction to type data at the keyboard. Used to indicate the first mention of an important concept. Used to highlight important details in text or illustrations and to indicate user actions. Used to represent file names or menu options to be selected. Also refers to section names. Blocks of text used to advise of related information. Notices used to emphasize very important information.

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System Overview
The 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 Overview
All the systems use a violet laser. MAKO 2, MAKO 2x, MAKO 4, and MAKO 4x are for commercial printing environments, whereas the MAKO NEWS is for newspaper publishing. All the systems perform the same basic functions and are operated the same way. The main differences between the systems include the imaging resolutions and media sizes they support, and the type of pinch mechanism they use (see the feature comparison tables on the next page).
Note: This manual makes no distinction between systems except where necessary. In the presentation that follows, except where otherwise noted, all references to the platesetter or the system pertain to any system in the series.

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Table 1 - 1 FEATURE COMPARISONS

SYSTEM
1016 MAKO 2 CTP MAKO 2X CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS 40.0 47.2 50.0 59.0 70.9 80.0 94.5 100.0 120.0 140.0
(DOTS PER MILLIMETER)

RESOLUTIONS
(DOTS PER INCH)

1200

1270

1500

1800

2032 2400

2540

3048

3556

SYSTEM
Maximum Edge Register
MAKO 2 CTP MAKO 2 CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS CTP
Notes:

PLATE SIZE (MM)

Maximum Notch Register
560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 660 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)

Minimum Edge Register

228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L)

560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 635 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)

1. (W) and (L) designate the width and length of the plate in millimeters (mm). 2. Edge Register: maximum plate size (edge to edge imaging) using an edge-register pin bar. 3. Notch Register: maximum plate size (edge to edge imaging) using an notch-register pin bar. The notch register plate size requires a minimum 12 mm notch depth, except System 4x, which requires a minimum 11 mm notch depth. 4. Minimum Edge Register: Minimum plate size. The minimum plate size of 252 mm (L) requires a custom pin bar on all 4-page machines.

SYSTEM
Manual
MAKO 2 CTP MAKO 2X CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS CTP

PINCH MECHANISM
The operator uses a pinch bar to manually open and close the pinch rollers.

Automatic The platesetter automatically

opens and closes the pinch rollers.

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System Components
A complete system includes a control workstation, CtServer software, a power conditioner, and a platesetter.
CONTROL WORKSTATION*
IMAGING UNIT

CT SERVER SOFTWARE
CONTROL PANEL TRANSPORT UNIT

POWER CONDITIONER
REGISTRATION PIN BARS

* the monitor is ordered as an option

PLATESETTER

Figure 1-1 System Components

Platesetter
The platesetter images and outputs plates.

Workstation
The workstation connects directly to the platesetter and runs the CtServer software. Operating instructions for the workstation are provided with the workstation. The operator makes frequent use of the workstation when running the platesetter. For that reason, the workstation should be set up next to the platesetter.

CtServer Software
CtServer is used to send jobs to the platesetter. It is also used to define the plate and pin bar requirements for jobs and communicate that information to the platesetter, which displays the information on the control panel LCD.
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Some operating parameters that can be set in CtServer can also be set at the control panel. For these parameters, the CtServer setting always overrides the control-panel setting. The use and operation of CtServer is documented in the CtServer Users Guide, which is delivered as a PDF on the CtServer CD.

Power Conditioner
The power conditioner shields the system from as ac power spikes, voltage drops, and other electrical power disturbances. The platesetter, the control workstation, and the control workstation monitor must all be plugged into the power conditioner, which in turn must be plugged into a grounded ac power outlet.
Platesetter System
POWER CONDITIONER
AC INLET AC OUTLETS

AC MAINS

AC Power

AC Power

Customer-supplied Plate Processor

AC Power AC Power
AC INLET

RS-232* USB

AC INLET

AC INLET

PROCESSOR

PLATESETTER

Plate Line IF

WORKSTATION
(with CtServer)

Monitor

MONITOR

* Used by service personnel to run diagnostic programs.

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 conditioner, damage resulting from voltage spikes, brownouts, etc., will NOT be covered by the warranty.
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Main Parts of the Platesetter

Power 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 1hour warm-up period prior to imaging.
PINCH ROLLER BAR
(NOT PRESENT IN MAKO4 AND MAKO NEWS)

CONTROL PANEL PIN BAR POWER SWITCH MEDIA TRANSPORT OUTPUT SENSOR

INPUT SENSOR
(NOT PRESENT IN MAKO 4 AND MAKO NEWS)

BACK

INPUT TRAY PEDESTAL

FRONT

POWER CORD FAN FILTER

Figure 1-3 Main Parts of the Platesetter

Power Cord
The power cord plugs into a receptacle located just below the power switch.

Pin Bar
The pin bar is used for plate registration. There are two types of pin bars: press notch registered and edge registered.
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Two pin bars come with the system as standard equipment. Additional pin bars can be ordered as an option. Exposing sets of plates with different registration notch requirements is easily accomplished by changing the pin bar.

Control Panel
The control panel allows you to interact with the platesetter. Commands and options are controlled through this device.

Input Tray
The input tray is used to position the plate for exposure. The plate is placed on the input tray and gently slid to engage the registration pins. A groove is provided in the surface of the input tray to provide a convenient place to push the plate forward. A plate cannot be loaded until the previous plate has been completed.

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.

AG111334 Rev. 2

PINCH ROLLER BAR *

PINCH ROLLERS

* SHOWN IN THE UP (OPEN) POSITION

Figure 1-4 Pinch Roller Bar

Fan Filters
The platesetter uses 2 fan filters. The filters slide into slots on either side of the unit. See Figure 1-3 on Page 5.
Note: To avoid damaging the filters, when lifting the platesetter off the pedestal, do not grasp the platesetter at points where the filters are located.

The Media Transport

The media transport automatically delivers the exposed media to a customer-supplied online processor.

The Pedestal
The pedestal is a specially designed base for the platesetter.

AG111334 Rev. 2

System Requirements
Safelighting
The platesetter is designed to be operated in a safelight environment.

Power and Heat Dissipation

Power (maximum) Heat Dissipation 90 - 264 Volts; 3 Amps; 250 Watt 50/60Hz, single phase. 850 BTU/hour

Environmental Requirements
TemperatureHumidity 62 - 86 degrees F (17 - 30 degrees C) 45 - 65%, non-condensing.

Note: Operating the system outside of the ranges specified above may affect performance.

AG111334 Rev. 2

Laser Safety
Laser Product Classification
The system is classified as a Class one (I) laser product. This classification means the operator is not exposed to hazardous laser light during operation and maintenance. The laser in the system is a Class Four (IV) device which emits visible laser light that is considered hazardous by FDA published limits.

IMPORTANT WARNING
Use of controls or adjustments or performance of procedures other than those specified in this guide may result in hazardous laser light exposure.

System Laser Wavelength Identification Label

The 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.

MEDIA SENSITIVITY
405 nm VISIBLE
Figure 1-5 Media Sensitivity Label

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Regulatory Information
Electromagnetic Emissions
DOC - Canada The Canadian Department of Communications requires compliance with the Radio Interference Regulations, ICES -003. This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. EMC Directive - Europe Complies with EN 55011: 1998 This is a Class A product. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. FCC - USA The standards for electromagnetic emissions are Part 15, Subpart J of the FCC rules. The system was tested to Class A limits. The following statements are required by the FCC: Changes or modifications to this unit not expressly approved by the party responsible for compliance could void your authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction guide, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to
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correct the interference at his or her own expense. Compliance with applicable regulations depends on the use of shielded cables. The user is responsible for procuring the appropriate cables.

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

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System Operation
Introduction

The same basic operating procedures apply to all models in the series. Except where otherwise noted, all the information that follows pertains to every model in the series.

Starting Up the System

The 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 Users Guide. Note: It is recommended that the system be powered on for a 1hour warm-up period prior to imaging.

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Shutting Down the System

Shut 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 workstations communication link with the platesetter is broken. To reestablish the link, power down the workstation, restart the platesetter, and then power up the workstation.

Using the Control Panel

When 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.
LEDS
EXPOSE ATTENTION ERROR

LCD

PREV

NEXT

OK

Accessing Menus
Access menus from the system control panel. Enter the menu subsystem by pressing MENU from the ONLINE state.

MENU

SELECT

CANCEL

KEYPAD

Figure 2-1 Control Panel

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AG111334 Rev. 2

Keys
PREVIOUS

PREVIOUS - Moves you backward within the menu or moves the cursor backward within the current menu item. ENTER - Enter or exit the menu sub-system by pressing MENU from the ONLINE state. NEXT - Moves you forward within the menu or moves the cursor forward within the current menu item. START - Starts exposing the loaded plate. Also, from anywhere in a numeric field, causes the next menu item to be displayed. In the last item of a menu, causes a return to the first item of the menu. SELECT -Increments the numeric digit under which the cursor is positioned or scrolls through the options available for the current menu item CANCEL - Cancels a pending load plate request, but does not stop a job that is in progress. STOP - The Emergency stop button. This button will stop all moving parts of the platesetter.

MENU

NEXT

OK

SELECT

CANCEL

LEDs
EXPOSE

.Green LED that indicates the plate is being exposed when it is flashing. Additionally, indicates registration pin contact when loading a plate. Yellow LED indicates there is a condition that requires operator attention. The LCD display indicates what needs to be done. Red LED that indicates a platesetter error condition. The LCD display indicates what the error is.

ATTENTION

ERROR

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Operator Menus
There are three operator menus:
User Preference Menu (see page 17). User Maintenance Menu (see page 22). Test Pattern Menu (see page 24).

Menu Selection
Follow these steps to set the parameters in any menu.
Step 1. Press MENU to enter the user menu system. Step 2. Press SELECT until the sub-menu you want displays on the LCD. Step 3. Press NEXT to enter the selected sub-menu. Step 4. Set the parameter to what you want. Step 5. Press SELECT to change the value. Step 6. Press NEXT to go to the next parameter until you have completed your selections. Step 7. Repeat steps 4 and 5 until all changes are made. Step 8. Press MENU to exit the user menu system.
ONLINE
MENU

USER PREFERENCES
NEXT

SELECT

SELECT

SELECT

TEST USER MAINTENANCE PATTERNS

NEXT

TEST PATTERNS
NEXT

Figure 2-2 User Menu Structure

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User Preference Menu

UNITS OF MEASURE OPTIONS ENGLISH (inches) or METRIC (millimeters)

The selected units of measure apply to all numeric measurement values in various menus. AUDIO ALERTS OPTIONS ENABLED or DISABLED

This menu item allows you to disable or to enable the audible alarms for the following conditions: Error conditions, Power-up, Image complete HORIZONTAL MAGNIFICATION LIMITS 85.00% to 110.00%

Sets the size of the image in the horizontal direction from 85% to 110% of nominal.
Note: The CtServer magnification setting overrides the control panel setting.

VERTICAL MAGNIFICATION LIMITS 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.

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User Preferences Menu

ONLINE
MENU

USER PREFERENCES
NEXT

SELECT

USER MAINTENANCE

SELECT

TEST TEST PATTERNS PATTERNS

SELECT

UNITS OF MEASURE
NEXT

ONLY 1 PIN BAR IN USE

NEXT

PROCESSOR SPEED
NEXT

AUDIO ALERTS
NEXT

IGNORE LASER TEMP. ERRORS

NEXT

REGISTRATION DELAY BEFORE PINCHING

NEXT

HORIZONTAL MAGNIFICATION
NEXT

USE TRANSPORT AS OUTPUT TRAY

NEXT

AUTOMATICALLY BEGIN IMAGING AFTER PINCHING

NEXT

VERTICAL MAGNIFICATION
NEXT

USE PLATELINE INTERFACE

NEXT

INDEXING IS ENABLED
NEXT

IMAGE OFFSET
NEXT

OVERLAP OUTPUTTING & IMAGING

NEXT

PRE IMAGE SETTLE TIME

NEXT

ONLINE

Figure 2-3 User Preferences Menu Map

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IMAGE OFFSET LIMITS -0.300 to +0.300 (-7.62mm to +7.62mm)

The image may be shifted to the left with a negative (-) value, or to the right with a positive (+) positive value. ONLY 1 PIN BAR IN USE OPTIONS: YES or NO

YES prevents the system from displaying a prompt to verify that the correct pin bar is installed whenever you open an autoloader cover. NO permits the system to display the prompt. IGNORE LASER TEMPERATURE ERRORS OPTIONS YES or NO

If the laser exceeds its target operating temperature an error will be reported. It is recommended that this problem be fixed. However, if critical jobs need to be completed, it is possible to operate the laser at a higher temperature. This operation is enabled by ignoring the laser temperature errors.
Note: Operating the laser at a higher temperature shortens the life of the laser.

OVERLAP OUTPUTTING AND IMAGING OPTIONS YES or NO

If this option is set YES, an operator can begin imaging another plate while the previous plate is feeding into the processor. PROCESSOR SPEED LIMITS 9.5 per minute to 77.9 (241 mm/min. to 1980 mm)

Should be set to match the speed of the online processor.

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USE TRANSPORT AS AN OUTPUT TRAY OPTIONS: YES or NO YES disables the media transport conveyor and effectively makes the transport function as an output tray. NO (the default setting) enables the conveyor to operate and transport plates to the processor. USE THE PLATELINE INTERFACE OPTIONS: YES or NO

YES enables the plateline interface to halt the platesetter when another device in the plate line is not ready to perform its function. NO causes the platesetter to ignore the plateline interface. This feature should be set to NO if a plateline interface is not being used. REGISTRATION DELAY BEFORE PINCHING PLATE LIMITS 0.10 seconds to 5.00 seconds Sets the length of time the system waits to close the pinch rollers after the plate is registered. The default setting is 0.50 seconds. AUTOMATICALLY BEGIN IMAGING AFTER PINCHING OPTIONS YES or NO YES enables the platesetter to automatically image the plate immediately after the pinch rollers close. NO disables the platesetter from doing so. When NO is selected, you must manually initiate imaging by pressing the OK button.

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INDEXING IS ENABLED OPTIONS YES or NO When YES is selected, the platesetter indexes the input rollers before starting each new image. When NO is selected, the platesetter does not index the rollers. This improves throughput, but may impact repaeatability and/ or registration.
Note: This feature is useful in systems that have an autoloader. If you have a manual load system, leave the feature set for the default (YES) setting.

PRE-IMAGE SETTLE TIME LIMITS 0.50 to 2.50 seconds The default setting is 2.00 seconds. Reducing the settle time improves throughput, but may decrease image quality at the leading edge of the plate.
Note: This feature is useful in systems that have an autoloader. If you have a manual load system, leave the feature set for the default (2.00) setting.

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User Maintenance Menu

PROGRAM VERSIONS This 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 TRANSPORT This user maintenance option will run the media transport until the STOP button is pressed. This function is used to clean the transport. RUN MEDIA ROLLERS This option runs the media rollers until the STOP button is pressed. This function is used to clean the rollers. DISPLAY ERROR LOG This user maintenance option presents system faults (up to a maximum of 20 faults) in chronological order. TIME is the elapsed time since the latest power on. SESSION # is the total number of times the system has been turned on. DEVICE NAME identifies the system component that failed. ERROR is an indication of the nature of the fault. DISPLAY LASER LOG This option presents status information about the system laser. The information is useful to service personnel, who sometimes request the information over the phone during service calls.

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User Maintenance Menu

ONLINE
MENU

USER PREFERENCES

SELECT

USER MAINTENANCE
NEXT

SELECT

TEST TEST PATTERNS PATTERNS

SELECT

NEXT

PROGRAM VERSIONS
SELECT

NEXT

RUN TRANSPORT
SELECT

Press NEXT to invoke the display or exercise the function.

NEXT

RUN MEDIA ROLLERS

SELECT

NEXT

DISPLAY ERROR LOG

SELECT

EXPOSE ATTENTION

ERROR

NEXT

DISPLAY LASER LOG

MENU SELECT

PREV

NEXT

OK

MENU

SELECT

CANCEL

ONLINE

Figure 2-4 User Maintenance Menu Map

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Test Patterns Menu

The 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 MODE OPTIONS Enabled or Disabled

This option moves the system in and out of test pattern mode. TEST PATTERN TYPE OPTIONS List of Test Patterns

Test Patterns are described fully in the system Reference guide and are for the use of qualified technicians only. NUMBER OF PLATES OPTIONS 1 to 60 plates

Sets the number of plates that will be imaged in the test session. REVERSE IMAGE POLARITY OPTIONS YES or NO

Reverses the test pattern images. YES will expose the background of the plate. NO will expose the image area. BAR WIDTH OPTIONS 1 to 999999 Pixels

Specifies the width of the lines in the Bar Test Patterns. BAR SPACING OPTIONS 1 to 999999 Pixels

This parameter specifies the width of the spaces between the lines in the Bar Test Patterns.
24 AG111334 Rev. 2

ONLINE
MENU

USER PREFERENCES

SELECT

USER MAINTENANCE

SELECT

TEST TEST PATTERNS PATTERNS

NEXT

SELECT

NEXT

SELECT

ENABLE

TEST PATTERN MODE

SELECT

NEXT

DISABLE

TEST PATTERNS SELECTION OPTIONS

GRID DROOP (MEDIA) DROOP (SCOPE) LASER RUN CONTINUOUSLY STEP WEDGE BARS (HORIZONTAL) BARS (VERTICAL) CHECKERBOARD
PRESS SELECT TO SCROLL THROUGH THE SELECTION OPTIONS. WHEN THE DESIRED OPTION APPEARS (FOR EXAMPLE, CHECKERBOARD) PRESS NEXT TO SET UP PARAMETERS FOR RUNNING THAT TEST.

NUMBER OF PLATES
NEXT

PLATE IS NOTCH REGISTERED

NEXT

NEXT

NEXT

EXPOSURE LEVEL
NEXT

DISTANCE FROM LEADING EDGE

NEXT

PLATE WIDTH
NEXT

HORIZONTAL MAGNIFICATION
NEXT

NEXT

PLATE LENGTH
NEXT

VERTICAL MAGNIFICATION
OK NEXT

ONLINE

Figure 2-5 Typical Test Pattern Menu Map (Checkerboard selected)

AG111334 Rev. 2

Only applies if Plate is Notch Registered is set to YES.

REVERSE IMAGE POLARITY

NOTCH DEPTH

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IMAGE LENGTH OPTIONS 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 RESOLUTION By picking any of the optional values, you set the horizontal resolution to that value. Horizontal Resolution is not displayed if a GRID test pattern is selected. OPTIONS 1200, 1270, 1800, 2400, 2540, 3048 and 3556 (dpi) 47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0 (dpmm)
Note: Resolution is model dependent. Your options may differ from those listed above. See Table 1 - 1, FEATURE COMPARISONS, on page 2.

VERTICAL RESOLUTION OPTIONS 1200, 1270, 1800, 2400, 2540, 3048 and 3556 (dpi) 47.2, 50.0, 70.9, 94.5, 100.0, 120.0, 140.0 (dpmm) By picking any of the optional values, you set the vertical resolution to that value. Vertical Resolution is not displayed if a GRID test pattern is selected.
Note: Resolution is model dependent. Your options may differ from those listed above. See Table 1 - 1, FEATURE COMPARISONS, on page 2.

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PLATE WIDTH OPTIONS 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 LENGTH OPTIONS 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 REGISTERED OPTIONS 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.

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NOTCH DEPTH OPTIONS 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 EDGE OPTIONS 1.665 to 37.873 or 42.3 mm to 961.9 mm

This options specifies the distance from the leading edge of the plate to the center of the notch that is closest to the leading edge. This parameter is only for notch-registered plates. EXPOSURE LEVEL LIMITS 000 to 255

This menu entry sets the exposure level at the media. The higher the number, the higher the exposure. HORIZONTAL MAGNIFICATION LIMITS 85.00% to 110.00%

Sets the size of the image in the horizontal direction from 85% to 110% of nominal. VERTICAL MAGNIFICATION LIMITS 85.00% to 110.00%

Sets the size of the image in the vertical direction from 85% to 110% of nominal.

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Equipment Configuration Displays

These 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
THE SCREENS DISPLAY THE FOLLOWING INFORMATION ABOUT YOUR SYSTEM: ------------------ DISPLAY 1 ----------------MACHINE TYPE* SYSTEM CONFIGURATION
DISPLAY 1
SELECT

ONLINE
SELECT

CONTROLLER P/N / MACHINE ID # FIRMWARE LASER POWER/FILM SENSITIVITY/OPTICAL EFFICIENCY

SYSTEM CONFIGURATION
DISPLAY 2
SELECT

---------------- DISPLAY 2 --------------OUTPUT TYPE SPINNER MOTOR

-------------------------------------------------------------------

Figure 2-6 Configuration Displays

AG111334 Rev. 2

29

Display Messages
During operation, the system displays status messages about the condition of the system and the progress of any jobs in process. The status messages appear on the control display. - The system is starting the spinner and moving the plate to the recording start position.
PREPARING TO EXPOSE EXPOSING IMAGE

- The system is now recording an image.

EJECTING PLATE -

Exposing is complete and the plate is being ejected onto the plate transport.

- Plate has been ejected from the rollers and is moving to the processor.
MOVING TO PROCESSOR FEEDING PROCESSOR EJECTING PLATE ONLINE

- Plate is on the transport and the leading edge of the plate is moving into the processor. - Exposing is complete and the plate is being ejected onto the plate transport. - The normal operating mode for the system
STARTING SPINNER TEST PATTERNS

- This message is accompanied by a progress bar when preparing to start an image and the spinner motor is - Test Patterns mode has been selected in the Test Patterns Menu and the system is ready to produce a test pattern. This mode of operation should be used by qualified service technicians only. The system is performing initialization functions prior to going online.

INITIALIZING -

Note: On a MAKO System 4, if the Pinch Roller bar is down, you will be prompted to raise it during initialization.

The system is waiting for the laser to reach its operating temperature.

WAITING FOR LASER -

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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.
10 12 13 14 14 15 15 11 1 2 3 4 5 6 7 8 9

10

12

Figure 2-7 Example Step-Wedge Test Strip When the test strip is taped over the plate, clear step 1 allows virtually all of the energy in the imaging beam to hit the plate, step 2 slightly less energy, step 3 still less energy, etc.

AG111334 Rev. 2

13

11

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.
5 10 12 13 14 14 15 15 11 5 7 1 2 3 4 6 8 9

10

12

Figure 2-8 Typical Step-Wedge Test Plate Image The distribution of dark steps, transition steps, and light step varies depending on the platesetters exposure setting, the plate type being used, and the state of the processor chemistry.

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 21step wedge (ECRM PH0389) on all other plates.

32

AG111334 Rev. 2

13

11

Step 2. Center the test strip on the plate 6 inches (15.2 cm) back from the leading edge, as shown below. Be sure to use two pieces of tape. Make sure the emulsion side of the step wedge faces the emulsion side of the plate.

Leading Edge of Plate

TAPE

STEP WEDGE TEST STRIP

Centerline of Plate
6 inches 15.2 cm

TAPE

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. 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 (normally 100%). Step 12. Set Magnification Vertical to the magnification being used (normally 100%). Step 13. Select MENU. Step 14. Press the SELECT key to begin exposing the test plate. The system exposes 100% of the first 8 inches of the plate at the exposure setting selected. After exposure, the plate moves onto the transport belt and advances until the leading edge of the plate is detected by the transport exit sensor. The transport then stops, the warning light on the top cover flashes, and a prompt to open the transport cover and remove the step wedge displays on the control panel.

Note: Note: In step wedge test pattern mode, the machine will not beep or report cover interlock open messages.
Step 15. On the front panel, press OK. The transport feeds the plate into the processor. Step 16. Process the plate. Step 17. Evaluate the output.

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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 WEDGE SCALE

2

3 4 5 6

3 4 5 6

No brush marks appear. Solid Step # may be visible. Approximately 50% Tail* exposure of area. Brush marks visible. Some minimal ghosting Clear may appear.

Step 3. Refer to the * Sometimes called Ghost or Scum, Tail steps table below for exhibit only partial exposure of the plate. exposure step wedge values for Figure 2-10 several popular plate types. The values shown in the table are for an ideal testing environment. Plate lot, plate age, processing conditions, and processor chemistry can have a dramatic effect on step wedge results. Always check these factors if your step wedge test results significantly differ from those shown in the table.

Plate Manufacturer
Fuji Lastra KPG Agfa

Plate Product Name

LP-NV LV-2 Violet Plate N91V

Step Wedge Test Strip

PH0388 PH0389 PH0389 PH0389

Step Wedge Values when Exposure is Correct

Solid 3, Scum 4 or 5 Solid Step 3 to 4+, Tail 5 and up Light tail 5 Solid 3, Scum 5

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Step 4. Example Figure 2-11 below shows how Fuji LP-NV test plates look for different exposure settings. Use the figure as a guide for evaluating your test output. If necessary, increase/decrease the platesetters exposure setting and then run another wedge test.
10 12 13 14 14 14 14 14 14 15 15 15 15 15 15 11 1 2 3 4 5 6 7 8 9

10

12 12 12 12 12

CORRECT EXPOSURE SETTING

10

B
10 EXPOSURE SETTING TOO HIGH 13 13 13 11 1 2 3 4 5 6 7 8 9

10

10

EXPOSURE SETTING TOO LOW

Figure 2-11

36

11

C
1 2 3 4 5 6 7 8 9

11

AG111334 Rev. 2

13

11

13

11

A
1 2 3 4 5 6 7 8 9

Media Handling
Media Specifications
L = Length Configurations
Prepunched Press Grooves or Edge Register

3
W = Width

Media Thicknesses
5.5 mil (0.14mm) 6 mil (0.15 mm) 8 mil (0.20mm) 10 mil (0.25mm) 12 mil (0.30mm)

MEDIA

Figure 3-1 Media Orientation

Plate Sizes
SYSTEM
Maximum Edge Register
MAKO 2 CTP MAKO 2X CTP MAKO 4 CTP MAKO 4X CTP MAKO NEWS CTP

PLATE SIZE (MM)

Maximum Notch Register Minimum Edge Register

560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 635 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)

560 mm (W) x 670 mm (L) 560 mm (W) x 670 mm (L) 615 mm (W) x 745 mm (L) 660 mm (W) x 960 mm (L) 635 mm (W) x 960 mm (L)

228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L) 228 mm (W) x 252 mm (L)

Safelight Requirement
The platesetter is designed to be operated in a safelight environment. All media handling must be done under safelight conditions. Safe working time varies with manufacturer. See the plate manufacturers specification for safelight recommendations.
AG111334 Rev. 2 37

Installing and Removing the Pin Bar

The pin bar provides alignment points that insure accurate plate registration. There are two types of pin bars: notch-registered and edgeregistered. 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. Note: MAKO 2x, MAKO 4x and MAKO NEWS models do not have a pinch roller bar.
PINCH ROLLER BAR

CHANNEL

INPUT TRAY

PIN BAR

Figure 3-2 Pin Bar Location

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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.

LATCH ALIGNMENT PIN

REGISTRATION PINS

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).

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39

FRONT OF CHANNEL

HOOK

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 alignment 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.

40

AG111334 Rev. 2

Step 7. Firmly press the center of the pin bar down to insure it is properly seated.
ALIGNMENT PIN HOOK

PIN BAR

CHANNEL

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.

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41

Loading Media
CtServer will request a pin bar and plate to be loaded, and the platesetter will prompt you to load the plate. One of the following prompts appears on the control panel LCD:
LOAD A PLATE <plate name> <bar name>

This message indicates that the next plate to be imaged is the same as the preceding plate. It is a prompt for you to load the same kind of plate that was just imaged.
LOAD A NEW PLATE <plate name> <bar name>

This message indicates that the next plate to be imaged is different than previous plate, but that it uses the same pin bar. It is a prompt for you to load the new (different) type plate.
VERIFY BAR AND LOAD <plate name> <bar name>

The meaning of this message depends on when it appears during the CtServer (host computer) session. When the session is first opened, it is a prompt for you to ensure that the correct pin bar is installed before loading the first plate, and then to load the plate. Subsequently in the session, the message indicates that the next plate to be imaged is different than the preceding plate AND requires a different pin bar. Thus, it is a prompt for you to change the pin bar and load the new (different) plate. The technique used for loading plates is a key in achieving good plate registration. Always handle and position the plate gently and carefully. Thin plates are especially susceptible to dings and dents.

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AG111334 Rev. 2

PINCH ROLLER BAR*

(Not present in MAKO 2x, MAKO 4x and MAKO NEWS models)

POWER SWITCH MEDIA TRANSPORT CONTROL PANEL PIN BAR

INPUT TRAY FAN FILTER

BACK

PEDESTAL

FRONT

* MAKO 4x and MAKO NEWS models have an automatic pinch mechanism.

Figure 3-6 External View of the System

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43

Loading Edge-registered Plates in a MAKO 2 or MAKO 4

Step 1. Face the front of the platesetter. Note: For instructions for loading an edge-registered plate in a system with an automatic pinch mechanism, refer toLoading Edge-registered Plates in a MAKO 2x, MAKO 4x or MAKO NEWS System on page 49.

Step 2. Raise the pinch roller bar to open the pinch rollers. Be sure the pinch roller is fully raised. If it is not, the green Expose LED on the control panel will not light.

Step 3. Verify the requested pin bar is loaded. If it is not, change the pin bar. Step 4. Place the requested plate on the input tray. Step 5. Push the plate to the left (Figure 3-7, A) so that the edge of the plate contacts the registration pins in the pin bar.
PINCH ROLLERS

REGISTRATION PIN PIN BAR EDGE OF PLATE

REGISTRATION PIN PLATE

A B
Figure 3-7 Loading Edge-registered Plates

Step 6. Push the plate forward into the platesetter (Figure 3-7, B) until you feel it make contact with a third registration pin that is inside the platesetter.
44 AG111334 Rev. 2

Step 7. Gently adjust the position of the plate as needed to get the green Expose LED to come on and stay on. This shows the plate is maintaining contact with all 3 registration pins (the 2 on the pin bar, plus the 1 inside the platesetter). If the LED goes out, you have lost pin contact. Move the plate out and to the right slightly, and then back in and to the left until the green LED stays on. Be careful to not apply so much pressure to the plate that the registration pins dent the plate. Use one finger/thumb to apply minimal pressure to the center of the plate. Note: If the green LED is not staying illuminated, the pin bar may not be fully seated. Remove and reinstall the pin bar, following the instructions above. Step 8. Holding the plate in position, lower the pinch roller bar. The green light will remain on if pin contact has been maintained and the platesetter will prompt for the OK button to be pressed to start imaging.
GREEN LED

EXPOSE

ATTENTION ERROR

PREV

NEXT

OK

OK

MENU

SELECT

CANCEL

Figure 3-8

Note: If the green LED does not stay illuminated, open the pinch roller bar and go back to Step 5. Step 9. Press the OK button. Imaging begins.
CAUTION - Never raise the pinch roller bar while a plate is being exposed. Doing so will cause the plate to jam inside the platesetter. For details, refer to Clearing Misfeeds, Manual Pinch Mechanism on page 58.

Step 10. After the plate is imaged, it is automatically transported from the platesetter to the on-line processor via the media transport.

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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 rollers. Be sure the pinch roller is fully raised. If it is not, the green Expose LED will not light. Note: For instructions for loading an edge-registered plate in a system with an automatic pinch mechanism, refer toLoading Notch-registered Plates in a MAKO 2x, MAKO 4x, or MAKO NEWS System on page 51.

Step 3. Verify the requested pin bar is loaded. If it is not, change the pin bar. Step 4. Place the requested plate on the input tray. Step 5. Position the plate so that both notches in the plate fully engage the two registration pins on the pin bar (see Figure 3-9 on Page 47).

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AG111334 Rev. 2

PINCH ROLLERS REGISTRATION PIN

NOTCH

PIN BAR PLATE PIN BAR REGISTRATION PIN

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, following the instructions above.
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 position the leading edge for exposing. Step 9. After the plate is imaged, it will automatically be transported out of the platesetter and into the on-line processor.

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AG111334 Rev. 2

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).
PINCH ROLLERS THIRD REGISTRATION PIN

Note: For instructions for loading an edge-registered plate in a system with a manually operated pinch mechanism, refer toLoading Edgeregistered Plates in a MAKO 2 or MAKO 4 on page 44.

A
PIN BAR EDGE OF PLATE

REGISTRATION PIN

PLATE

B
49

Figure 3-10 Loading Edge-registered Plates

AG111334 Rev. 2

Step 5. Push the plate forward (B in Figure 3-10) until it comes into contact with a third registration pin that is inside the platesetter. Step 6. Gently adjust the position of the plate until the green Expose LED stops blinking and stays on steady. (Steady on indicates the plate is making contact with all the registration pins). Step 7. The platesetter automatically lowers the pinch rollers. Note: The platesetter will not lower the pinch rollers until electronics sensors report that the plate is making good contact with all the registration pins. If the pin bar isnt properly seated in its mount, the sensors may not operate correctly and the platesetter may not close the pinch rollers. If you load a plate that it is making good contact with the registration pins but the pinch rollers dont close, try re-seating the pin bar. After the pinch rollers close, the platesetter does either of the following, depending on the setting of the Automatically Begin Imaging After Pinching menu option:
See User Preferences Menu on page 13. for more about the Automatically Begin Imaging After Pinching menu option.

automatically begins imaging the plate, or displays a PRESS OK TO BEGIN prompt on the control panel display. Step 8. If the prompt appears, press the OK button. Step 9. After the plate is imaged, it is automatically transported to the online processor via the media transport.

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AG111334 Rev. 2

Loading Notch-registered Plates in a MAKO 2x, MAKO 4x, or MAKO NEWS System
Step 1. Face the input tray. Step 2. Verify the requested pin bar is loaded. If it is not, change the pin bar. Step 3. Place the requested plate on the input tray. Note: For instructions for loading a notch-registered plate in a system with a manually operated pinch mechanism, refer toLoading Notchregistered Plates in a MAKO 2 or MAKO 4 on page 46.

Step 4. Position the plate so that both notches in the plate fully engage the two registration pins on the pin bar (see Figure 3-11).
PINCH ROLLERS REGISTRATION PIN

NOTCH

PIN BAR PLATE PIN BAR REGISTRATION PIN

Figure 3-11 Loading Notch-registered Plates.

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 electronics sensors report that the plate is making good contact with all the registration pins. If the pin bar isnt properly seated in its mount, the sensors may not operate correctly and the platesetter may not close the pinch rollers. If you load a plate that it is making good contact with the registration pins but the pinch rollers dont close, try re-seating the pin bar. After the pinch rollers close, the platesetter does either of the following, depending on the setting of the Automatically Begin Imaging After Pinching menu option:
See User Preferences Menu on page 13. for more about the Automatically Begin Imaging After Pinching menu option.

automatically begins imaging the plate, or displays a PRESS OK TO BEGIN prompt on the control panel display.

Step 7. If the prompt appears, press the OK button. Step 8. After the plate is imaged, it is automatically transported to the online processor via the media transport.

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AG111334 Rev. 2

Maintenance and Troubleshooting

Introduction
This chapter discusses:
General Maintenance Moving the System

General Maintenance
This chapter explains how to keep the system in clean, working order. Remember to shut the power off to the machine prior to performing any internal maintenance procedures. Use only the recommended cleaner. Make sure the cleaning supplies are free of lint and dirt.

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53

PINCH ROLLER BAR

(NOT PRESENT IN MAKO 2X, MAKO 4X AND MAKO NEWS)

CONTROL PANEL PIN BAR POWER SWITCH MEDIA TRANSPORT OUTPUT SENSOR

INPUT SENSOR
(NOT PRESENT IN MAKO 2 AND MAKO 4)

INPUT TRAY

BACK

PEDESTAL

FRONT

POWER CORD FAN FILTER

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. Dont 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).

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AG111334 Rev.2

The filters can become clogged with dust and other debris if it is not cleaned regularly. A clogged filter can result in the loss of internal pressure and increase the possibility of a system malfunction. Clean the filters whenever they show signs of contamination with dust or other debris Heres how to remove and replace a filter:
Step 1. Turn the power switch off. Step 2. From inside the pedestal, reach up and under the machine where the on/off switch is located. See Figure 4-3. Step 3. Place your fingers on the filter. It has a corrugated feel. Step 4. Gently push the filter toward the outside of the machine until the filter protrudes from the slot shown below.

Figure 4-2

ON/OFF SWITCH

FAN FILTER

SLOT

PEDESTAL

Figure 4-3 Fan Filter Removal

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 contaminate 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-

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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 sensor located beneath the input tray (see Figure 4-1). Clean the sensor by gently rubbing the sensor with a cotton tip swab moistened 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 Mechanism

Two 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 2 When an edge-registered pin bar is used, a third internal registration pin is activated. The location of this pin (which you can feel but not see when you load a plate) is shown below in Figure 44. The pin moves up into the media path when the pinch mechanism is raised, and it drops below the media path when the mechanism is lowered.

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AG111334 Rev.2

INTERNAL REGISTRATION PIN

REAR PINCH ROLLER

REGISTRATION PIN

FRONT PINCH ROLLER

PLATE

PIN BAR

NOTE The Internal Registration Pin goes up when the Pinch Roller Bar is raised and goes down when the Pinch Roller Bar is lowered.

REGISTRATION PIN

Figure 4-4 Internal Registration Pin During imaging, the registration pin is below the plates path of travel. If a misfeed or a power failure happens to occur and the plate gets hung up in the machine with a manual pinch mechanism, you are advised not to raise the pinch roller bar. Doing so will raise the registration pin. If the plate happens to be positioned over the registration pin (Figure 4-5 View B), when the pin comes up and it will bend or dent the plate.

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59

INTERNAL REGISTRATION PIN

PLATE

PLATE

VIEW A Plate not over the pin

VIEW B Plate over the pin

Figure 4-5 Plate Positions over the Registration Pin To insure against this happening, use the following procedure to remove the plate:
Step 1. Do not raise the pinch roller bar or power off the machine. Step 2. Use the control panel PREV and NEXT buttons as follows to extract the plate: Press the PREV button to effect a movement of the plate toward the front of the machine, and then press the button again to stop the movement. Press the NEXT button to effect a movement of the plate toward the back of the machine, and then press the button again to stop the movement.

Step 3. Exercise the PREV and NEXT buttons as required until the plate out all the way of the machine.

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AG111334 Rev.2

Step 4. Press the OK button. This turns off the blinking error light and clears the the error message from the display. Step 5. Resume normal operation.

Moving the System

When 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.

LEVELING FEET

Figure 4-6 Levelling Feet Location

Step 3. Retract all four levelling feet so the system rides on its wheels and

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place the system in its new location. Step 4. Turn all four levelling feet of the platesetter down until they just touch the floor. Step 5. Continue to turn leveling feet until the system is level, front to back and side to side.

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AG111334 Rev.2

A AUDIO ALERTS menu item 17 AUTOMATICALLY BEGIN IMAGING AFTER PINCHING menu item 20 B BAR SPACING menu item 24 BAR WIDTH menu item 24 C CANCEL key 15 Cleaning 57 back media rollers 57 fan filters 54 front media rollers 56 media transport belt 57 media transport output sensor 57 system exterior 54 Clearing misfeeds 58 Control panel 6 Controller board, part number 22 Controller ID 29 CtServer software functions of, 3 overriding control panel settings, 4 users guide, 4 D DISPLAY ERROR LOG menu item 22 DISPLAY LASER LOG menu item 22 Display messages 30 DISTANCE FROM NOTCH TO LEADING EDGE menu item 28 E ENTER key 15 Environmental specifications 8 Equipment configuration displays 29 EXPOSURE LEVEL menu item 28 Exposure, setting 28, 31 F Fan filters 54 avoid grasping, 7 location of, 7 removing 55 replacing 56 Firmware, version of 22

H Heat, see System specifications HORIZONTAL MAGNIFICATION menu item 17, 28 HORIZONTAL RESOLUTION menu item 26 I Identification label, location of 11 IGNORE LASER TEMPERATURE ERRORS menu item 19 IMAGE LENGTH menu item 26 IMAGE OFFSET (VERTICAL) menu item 26 IMAGE OFFSET menu item 19, 20, 21 INDEXING IS ENABLED menu item 21 Input tray 6 J Jams, see Clearing misfeeds L l 44 Laser classifiication, 9 power of, 29 safety concerns, 9 warning, 9 LEDs green 15

does not light, 44 does not stay on, 45

red 15 yellow 15 Loading plates see Plate (loading) M Magnification 17 MAKO CTP series systems included in, 1 Media transport disabling operation of, 20 function of, 7 Menus accessing, 14 setting parameters in, 16 Test Patterns Menu 24 User Maintenance Menu 22 User Preference Menu 17 Models, differences between 1 Moving the system 61

N NEXT key 15 NOTCH DEPTH menu item 28 NUMBER OF PLATES menu item 24 O ONLY 1 PIN BAR IN USE menu item 19 OVERLAP OUTPUTTING AND IMAGING menu item 19 P Parameter settings CtServer vs. control panel, 4 Parameters, setting 16 Pedestal 7 Pin bar ensuring the correct one is used, 38 function of, 5 installing a, 38 not seated correctly 47 ordering an additional, 6 types of, 6, 38 Pinch roller bar guidelines for using, 6 purpose of, 6 Pinch rollers fail to automatically close (System 4x) 52 function of, 6 Plate loading a notch-registered plate

PRE-IMAGE SETTLE TIME menu item 21 PROCESSOR SPEED menu item 19 PROGRAM VERSION menu item 22 R REGISTRATION DELAY BEFORE PINCHING PLATE menu item 20 Registration pins operation of the "hidden" pin 58 the third "hidden" pin 50 the third "hidden" pin, 58 Regulatory information 10 REVERSE IMAGE POLARITY menu item 24 RUN MEDIA ROLLERS menu item 22 RUN TRANSPORT menu item 22 S Safelight requirement 8, 37 SELECT key 15 Sending a job 13 Shutting down the system 14 Specifications, see System specifications Spinner motor 29 START key 15 Starting the system 13 Step wedge test 31 purpose of, 31 test strip, 32 STOP key 15 System components diagram of, 3 list of, 3 System specifications ac power, 8 heat dissipation, 8 humidity, 8 temperature, 8 T TEST PATTERN MODE menu item 24 TEST PATTERN TYPE menu item 24 TEST PATTERNS menu 24 TEST PATTERNS menu item 24 U UNITS OF MEASURE menu item 17 USE THE PLATELINE INTERFACE menu item 20 USE TRANSPORT AS AN OUTPUT TRAY menu item 20 USER MAINTENANCE menu 22

in

MAKO 4x or MAKO NEWS 51 in the MAKO 2 or MAKO 4 46

loading an edge-registered plate

in

MAKO 4x or MAKO NEWS 49 in the MAKO 2 or MAKO 4 44

sizes 37 thicknesses 37 PLATE IN NOTCH REGISTERED menu item 27 PLATE LENGTH menu item 27 PLATE WIDTH menu item 27 Power conditioner functions of, 4 required use of, 4 Power cord receptacle 5 Power switch function of, 5 location of, 5

USER PREFERENCE menu 17 V VERTICAL MAGNIFICATION menu item 17, 28 VERTICAL RESOLUTION menu item 26 W WAITING FOR LASER message 30 Warm-up period 5, 13 Warranty issues 4 Workstation function of, 3 operating instructions for, 3

NOTES