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FFEI Ltd. Block 2, Eaton Court Eaton Road Hemel Hempstead Herts, HP2 7DR United Kingdom

FFEI Ltd. Block 2, Eaton Court Eaton Road Hemel Hempstead Herts, HP2 7DR United Kingdom

Tel: +44 01442 213440 Fax: +44 01442 210579 www.ffei.co.uk Registered Number: 3244452

©2007

+44 01442 210579 www.ffei.co.uk Registered Number: 3244452 ©2007 LUXEL V- 6 S ERIE S C TP

LUXEL V-6 SERIES CTP

INSTALLATION GUIDE

6800154011

PRELIMINARIES

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

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

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

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

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

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

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

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

LUXEL V-6 SERIES CTP

Electromagnetic Compatibility Notice - USA

This equipment has been tested and found to be compliant with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial envi- ronment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense.

Electromagnetic Compatibility Notice - Europe

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

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

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

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

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

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

This equipment conforms to the requirements of EC directives:

• 73/23/EEC - Low Voltage Directive

• 89/336/EEC - EMC Directive.

PRELIMINARIES

About this Manual

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

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

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

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

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

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

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

LUXEL V-6 SERIES CTP

TABLE OF CONTENTS

Chapter 1 Introducing the Luxel V-6 Series

The Luxel V-6 Series CTP System

1-1

Luxel V-6e Manual and Semi-Auto

1-2

Luxel V-6 Manual

1-3

Luxel V-6 Semi-Automatic

1-4

Luxel V-6 Single-Cassette (SAL)

1-5

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

1-7

Network Connections

1-8

Loading Applications and Options

1-9

Completing the Installation Report

1-9

Chapter 2 Safety on the Luxel V-6

Health and Safety at Work

2-1

Warnings and Cautions

2-2

Clothing and Jewellery

2-2

Equipment and Tools

2-2

Site Safety Rules

2-2

Safety Labels and Indicators

2-3

Mains Rating Label

2-3

Drum and Traverse Warning Labels

2-4

Autoloader Warning Labels

2-5

Autofeeder Warning Labels

2-5

Optics Warning Labels

2-9

Electrical Warning Labels

2-10

PRELIMINARIES

Interlock Warning Labels

2-11

Safety Devices

2-14

Unattended Equipment

2-14

Dust Prevention

2-14

Plate Handling

2-14

Electrical Safety

2-15

Mechanical Safety

2-15

Spinner Safety

2-16

Moving Parts Safety

2-16

Acoustic Noise Safety

2-16

Safety Interlock System

2-16

Interlocked Covers

2-16

Locked Covers

2-19

Interlock Over-rides

2-19

Laser Safety

2-21

Laser Precautions

2-22

Laser Safety Shutter

2-22

Laser Safety Warnings

2-23

A DLA Room

2-24

A DLA

Curtain

2-24

Chapter 3 Unpacking and Handling

Unpacking the Equipment

3-1

Consignment Check

3-1

Inspection of Boxes

3-2

Unpacking the Modules

3-3

LUXEL V-6 SERIES CTP

Handling the Equipment

3-6

Using a Fork-Lift

3-7

Chapter 4 Installing Luxel Equipment and Soft- ware

Start the Installation

4-1

Special Tools Required

4-1

Pre-Install Checks

4-2

Check Floor Gradient

4-2

Remove the Module Covers

4-3

Remove V-6 Engine Top Cover

4-5

Remove V-6e Engine Top Cover (Manual)

4-5

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

4-6

Heavy Lifting Operations

4-6

Installation Sequence

4-7

Semi-Automatic (Luxel V-6e)

4-7

Semi-Automatic (Luxel V-6)

4-7

Single-Cassette Fully-Automatic (Luxel V-6)

4-8

Multi-Cassette Autofeeder (Luxel V-6)

4-9

Install the Processor

4-9

Install the Engine

4-10

Remove Engine Transit Fixings

4-10

Traverse Carriage Transit Fixing

4-10

Platen Transit Fixings (V-6 Only)

4-12

Integrate the Processor and Engine

4-13

Set the Processor Height

4-13

Mate the Engine to the Processor

4-13

Level the Engine

4-15

PRELIMINARIES

Manual System

4-15

All Variants

4-16

Install the Autoloader (Luxel V-6)

4-17

Remove Autoloader Transit Fixings

4-17

Remove the MLS Transit Fixings

4-19

Mate the Autoloader and Engine

4-21

Level the Trolley and Cassette

4-24

Set the Second Trolley Height

4-28

Install the Multi-Cassette Autofeeder (MAL)

4-28

Integrate and Level the Autofeeder (Basic Level)

4-29

Connect the Autofeeder Cables

4-33

Remove Transit Fixings Using the Brake Override

4-37

Set up the Brake Override

4-38

Lower the Elevator

4-40

Raise the Elevator

4-40

Remove the Brake Override

4-40

Remove the Transit Fixings

4-40

Integrate and Level the Autofeeder (Fine)

4-43

Levelling the Trolley

4-46

Set up the System

4-48

Align Carriage and Ball Cage

4-48

Connect Power and Equipment

4-49

Attach the PAT Air Filtering System

4-51

Connect the Vacuum Pump

4-52

Connect the Processor Earth Cable

4-53

G&J Earth Cable Fitting

4-53

Heights (Inca) Earth Cable Fitting

4-55

Fitting the PC G10 Film Filter

4-55

LUXEL V-6 SERIES CTP

Plate

Output Alignment Checks

4-55

Clean Engine Drum

4-57

Install Luxel Desktop Applications and Device Driver

4-58

System Pre-Requirements

4-58

Installing the LuxelServer

4-59

Install the LuxelServer (Device Drivers)

4-59

Install the LuxelDesktop

4-59

Installing Licence Options and Upgrades

4-59

Obtaining Licence Keys

4-60

Chapter 5 Commissioning the Luxel V-6 System

Start to Commission the Platesetter

5-1

Initial Software Checks and Setups

5-2

Open Main Diagnostics and Check Engine Clock

5-2

Check Power Supply Voltages

5-3

Check Cover Interlocks

5-4

Check Engine Traverse Level

5-5

Set up the Processor (if Installed)

5-7

Setting up Optics and Imaging

5-8

Check Beam Focus

5-8

Calculating Values for 96 Resolution Test Strips

5-12

Calculating Values for 48 Resolution Test Strips

5-14

Calibrate for Laser Exposure

5-15

MMI

Menus (Luxel V-6)

5-15

PCI Menu (Luxel V-6e)

5-17

Check Registration and Tint Quality

5-17

PRELIMINARIES

Check Plate Registration

5-18

Expose a 50% Prediction Test Plate

5-18

Test Image Quality

5-20

Check Edge Detect Function

5-20

Checking Plate Output (without a Punch)

5-21

Check Image Skew Accuracy

5-21

Check Image Base and Edge Accuracy

5-22

Set Image Base Offset

5-23

Set Image Edge Offset

5-24

Checking Plate Output (with a Punch)

5-25

Punch Configuration Check

5-25

Check Image to Top of Plate Accuracy

5-27

Check Image to Punch Crop Accuracy

5-28

Check Image Base Position in RIP

5-29

Check for Image Centering

5-29

Installing the Remote Alert Forwarding

5-30

Preliminaries

5-30

Setup the Mail Configuration

5-31

Local Mail Server:

5-32

Web-Based Mail Servers

5-32

SMTP Authentication

5-32

Web-Based Mail Host

5-33

POP Authentication

5-33

Configure the Alert System

5-35

Chapter 6 Demonstrating the Luxel V-6 System

Demonstrate the Platesetter Platesetter Safety and Interlocks

Demonstrate the Platesetter Platesetter Safety and Interlocks

6-1

6-2

LUXEL V-6 SERIES CTP

Laser Safety

6-2

Electrical Safety

6-2

Mechanical Safety

6-2

Accessing the Platesetter

6-2

Using the MMI (V-6 Option) and PCI

6-2

Platesetter Maintenance

6-3

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

6-3

Emptying the Interleaf Bin (Single- and Multi-Cassette)

6-3

Cleaning the Spinner Mirror

6-3

Checking the Platesetter Environment

6-3

Vacuum Clean the Platesetter

6-3

Recovering From Platesetter Errors

6-4

Operator Recovery From Media Jams

6-4

Recovery From System Errors

6-4

Loading Cassettes (Single- and Multi- Cassette)

6-5

Running the RIP

6-5

Switching On/Off Sequence

6-5

Calibrating the Platesetter Output

6-5

Ordering New Options

6-5

PRELIMINARIES

I NTRODUCING THE L UXEL V-6 S ERIES This chapter describes the main equipment modules

INTRODUCING THE LUXEL V-6 SERIES

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

1.1 The Luxel V-6 Series CTP System

1-1

1.2

Network Connections

1-8

1.1 The Luxel V-6 Series CTP System

This installation manual explains how to install the following Luxel B2 family of platesetters fitted with Violet laser optics and supplied options:

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

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

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

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

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

1-2

INTRODUCING THE LUXEL V-6 SERIES

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

1.1.1 Luxel V-6e Manual and Semi-Auto

A typical Manual Luxel V-6e platesetter is illustrated in Figure 1.1 on Page 1-2.

pl atesetter is illustrated in Figure 1.1 on Page 1-2 . INPUT/OUTPUT LOAD PLATEN Figure 1.1
pl atesetter is illustrated in Figure 1.1 on Page 1-2 . INPUT/OUTPUT LOAD PLATEN Figure 1.1

INPUT/OUTPUT

LOAD PLATEN

Figure 1.1 Luxel V-6e: manual

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

Engine with I/O load platen.

Processor (semi-automatic only).

PAT Air Filter.

Vacuum pump (external manufacturer supply).

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

RIP application software with the options of:

LUXEL V-6 SERIES CTP 1-3

Celebrant

Gateway

Rampage.

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

1.1.2 Luxel V-6 Manual

A typical manual V-6 platesetter system is illustrated in Figure 1.2

on Page 1-3.

system is illustrated in Figure 1.2 on Page 1-3 . ENGINE INPUT PLATEN Figure 1.2 Luxel
system is illustrated in Figure 1.2 on Page 1-3 . ENGINE INPUT PLATEN Figure 1.2 Luxel
system is illustrated in Figure 1.2 on Page 1-3 . ENGINE INPUT PLATEN Figure 1.2 Luxel

ENGINE

INPUT

PLATEN

Figure 1.2 Luxel V-6: manual

It comprises the following equipment and modules:

Engine with input platen.

PAT Air Filter (external manufacturer supply).

Vacuum pump.

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

RIP application software with the options of:

Celebrant.

1-4

INTRODUCING THE LUXEL V-6 SERIES

Gateway.

Rampage.

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

1.1.3 Luxel V-6 Semi-Automatic

A typical semi-automatic Luxel platesetter system is illustrated in Figure 1.3 on Page 1-4.

ENGINE PROCESSOR
ENGINE
PROCESSOR
ENGINE PROCESSOR INPUT PLATEN

INPUT PLATEN

Figure 1.3 Luxel V-6: semi-automatic

It comprises the following equipment and modules:

Engine with input platen.

PAT Air Filter (external manufacturer supply).

Vacuum pump.

Processor (external manufacturer supply).

Stacker (external manufacturer supply).

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

LUXEL V-6 SERIES CTP 1-5

RIP application software with options of:

Celebrant

Gateway

Rampage.

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

1.1.4 Luxel V-6 Single-Cassette (SAL)

A typical single-cassette Luxel V-6 platesetter without a Manual

Loading Slot (MLS) is illustrated in Figure 1.4 on Page 1-5. A V-6 with MLS is shown in Figure 1.5 on Page 1-6.

TROLLEY/ PROCESSOR CASSETTE ENGINE AUTOLOADER
TROLLEY/
PROCESSOR
CASSETTE
ENGINE
AUTOLOADER

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

A single-cassette comprises the following equipment and mod-

ules:

1-6

INTRODUCING THE LUXEL V-6 SERIES

Engine.

Autoloader with MLS option.

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

PAT Air Filter (external manufacturer supply).

Vacuum pump.

Processor (external manufacturer supply).

Stacker (external manufacturer supply).

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

RIP/PCI PC server (supplied separately by the customer). MANUAL LOAD SLOT Figure 1.5 Luxel V-6: single-cassette

MANUAL LOAD SLOT

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

RIP application software with options of:

Celebrant

Gateway

Rampage.

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

LUXEL V-6 SERIES CTP 1-7

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

A typical multi-cassette autoloader Luxel V-6 platesetter with an

autofeeder module is illustrated in Figure 1.6 on Page 1-7.

AUTOLOADERAUTOLOADER AUTOLOADERAUTOFEEDER
AUTOLOADERAUTOLOADER
AUTOLOADERAUTOFEEDER

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

A multi comprises the following equipment and modules:

Engine.

Autoloader.

Autofeeder.

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

PAT Air Filter (external manufacturer supply).

Vacuum pump.

Processor (external manufacturer supply).

1-8

INTRODUCING THE LUXEL V-6 SERIES

Stacker (external manufacturer supply).

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

1.2

Network Connections RIP S/W PCI S/W IMAGES FROM DESKTOP SYSTEMS * (ETHERNET/ TCP/IP) ENGINE F/W
Network Connections
RIP S/W
PCI S/W
IMAGES FROM
DESKTOP SYSTEMS *
(ETHERNET/
TCP/IP)
ENGINE F/W
PCI/RIP PC
DIAGNOSTIC
IMAGE DATA/
DATA
ENGINE CONTROL
(RS232)
(FIREWIRE)
PLATE
PROCESSOR
STACKER
NOT
SHOWN
SEE YOUR
RIP USER'S GUIDE/
PRE-INSTALLATION GUIDE
*
PROCESSOR
ENGINE
COMMS

A typical networked system is shown in Figure 1.7 on Page 1-8.

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

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

LUXEL V-6 SERIES CTP 1-9

1. Ethernet (or any suitable network): from the RIP PC to DTP sys-

tems (see documentation supplied with network equipment).

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

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

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

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

1.2.1 Loading Applications and Options

The Luxel V-6 system is shipped and tested with the following software with Release Notes available on SIO:

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

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

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

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

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

1.2.2 Completing the Installation Report

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

1-10

INTRODUCING THE LUXEL V-6 SERIES

S AFETY ON THE L UXEL V-6 To ensure a safe installation, engineers should follow

SAFETY ON THE LUXEL V-6

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

2.1 Health and Safety at Work

2-1

2.2

Safety Labels and Indicators

2-3

2.3 Safety Interlock System

2-16

2.4

Laser Safety

2-21

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

2.1 Health and Safety at Work

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

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

2-2

SAFETY ON THE LUXEL V-6

2.1.1 Warnings and Cautions

There are two safety categories given in this manual:

WARNINGS are given for conditions which may endanger life.

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

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

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

2.1.2 Clothing and Jewellery

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

2.1.3 Equipment and Tools

Use the approved service tools and the protection equipment required for laser and mechanical safety.

2.1.4 Site Safety Rules

Most accidents can be avoided if you follow these simple rules.

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

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

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

LUXEL V-6 SERIES CTP 2-3

2.2 Safety Labels and Indicators

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

2.2.1 Mains Rating Label

See Figure 2.1 on Page 2-3.

IMAGING ENGINE FULLY-AUTOMATIC (REAR) RATED AT 15 A
IMAGING ENGINE
FULLY-AUTOMATIC
(REAR)
RATED AT 15 A
K E L I T S ETL LISTED CONFORMS TO UL STD 60950 R C
K
E
L
I
T
S
ETL LISTED
CONFORMS TO
UL STD 60950
R
C
T
US
CERTIFIED TO
92206 CAN/USA STD C22.2 NO. 60950
Product:
LUXEL V-6 HD
Model No:
V6ENGINEM
E
Serial No:
E
Volts:
230
50 / 60Hz ~
Max Current:
10A
Manufactured:
T
This device complies with Part 15 of the FCC rules
and is subject to the following two conditions:
D
1.This device may not cause any harmful
interference
and
2.This device must accept any interference
received including interference that may
cause undesired operation.
This Class A digital apparatus complies
with Canadian ICES-003.
N
Cet appareil numerique de la classe A
est conforme a la norme NMB-003 du Canada.
This laser conforms to the applicable requirements of
21 CFR Sub chapter J.
FFEI LTD.
PETERBOROUGH
I
ENGLAND
CLASS 1 LASER
LASER KLASSE 1
LASER DE CLASSE 1
7550 854D 05

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

2-4

SAFETY ON THE LUXEL V-6

2.2.2 Drum and Traverse Warning Labels

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

LASER RADIATION AVOID DIRECT EYE EXPOSURE CLASS 2R LASER PRODUCT 0.8mW 635nm CW IEC 60825-1

LASER RADIATION

AVOID DIRECT EYE EXPOSURE

CLASS 2R LASER PRODUCT

0.8mW 635nm CW

LASER RADIATION AVOID DIRECT EYE EXPOSURE CLASS 2R LASER PRODUCT 0.8mW 635nm CW IEC 60825-1 Amendment
LASER RADIATION AVOID DIRECT EYE EXPOSURE CLASS 2R LASER PRODUCT 0.8mW 635nm CW IEC 60825-1 Amendment

IEC 60825-1 Amendment 2 / 2001

LASER RADIATION AVOID DIRECT EYE EXPOSURE CLASS 2R LASER PRODUCT 0.8mW 635nm CW IEC 60825-1 Amendment

Figure 2.2 Drum: moving parts and edge detect warning labels

LUXEL V-6 SERIES CTP 2-5

2.2.3 Autoloader Warning Labels

Figure 2.3 on Page 2-5 shows a moving parts label on the PTM feed head

Page 2-5 shows a moving parts label on the PTM feed head Figure 2.3 Plate feed
Page 2-5 shows a moving parts label on the PTM feed head Figure 2.3 Plate feed
Page 2-5 shows a moving parts label on the PTM feed head Figure 2.3 Plate feed

Figure 2.3 Plate feed moving parts

2.2.4 Autofeeder Warning Labels

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

2-6

SAFETY ON THE LUXEL V-6

WARNING ENSURE MAINS SUPPLY DISCONNECTED BEFORE SERVICING
WARNING
ENSURE MAINS SUPPLY DISCONNECTED
BEFORE SERVICING

Figure 2.4 Autofeeder: elevator motor warning labels

LUXEL V-6 SERIES CTP 2-7

L UXEL V-6 S ERIES CTP 2-7 Figure 2.5 Autofeeder: elevator warning label
L UXEL V-6 S ERIES CTP 2-7 Figure 2.5 Autofeeder: elevator warning label
L UXEL V-6 S ERIES CTP 2-7 Figure 2.5 Autofeeder: elevator warning label

Figure 2.5 Autofeeder: elevator warning label

2-8

SAFETY ON THE LUXEL V-6

USER SIDE
USER SIDE
2-8 S AFETY ON THE L UXEL V-6 USER SIDE SERVICE SIDE Figure 2.6 Autofeeder elevator
2-8 S AFETY ON THE L UXEL V-6 USER SIDE SERVICE SIDE Figure 2.6 Autofeeder elevator
SERVICE SIDE
SERVICE SIDE

Figure 2.6 Autofeeder elevator moving parts warning labels

L UXEL V-6 S ERIES CTP 2-9 AUTOFEEDER Figure 2.7 Autofeeder: earth wire safety label

LUXEL V-6 SERIES CTP 2-9

L UXEL V-6 S ERIES CTP 2-9 AUTOFEEDER Figure 2.7 Autofeeder: earth wire safety label 2.2.5

AUTOFEEDER

Figure 2.7 Autofeeder: earth wire safety label

2.2.5 Optics Warning Labels

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

2-10

SAFETY ON THE LUXEL V-6

2-10 S AFETY ON THE L UXEL V-6 Figure 2.8 Optics base: laser warning labels 2.2.6
2-10 S AFETY ON THE L UXEL V-6 Figure 2.8 Optics base: laser warning labels 2.2.6
2-10 S AFETY ON THE L UXEL V-6 Figure 2.8 Optics base: laser warning labels 2.2.6
2-10 S AFETY ON THE L UXEL V-6 Figure 2.8 Optics base: laser warning labels 2.2.6

Figure 2.8 Optics base: laser warning labels

2.2.6 Electrical Warning Labels

Figure 2.9 on Page 2-11 shows the area of risk from high-tension voltage inside the interlock box.

LUXEL V-6 SERIES CTP 2-11

Attention! high tension V orsicht! Hochspannung Preé caution! haute tension Precaucion! ó alta tensionó
Attention!
high tension
V orsicht!
Hochspannung
Preé caution!
haute tension
Precaucion!
ó
alta tensionó
Attention! high tension V orsicht! Hochspannung Preé caution! haute tension Precaucion! ó alta tensionó
Attention! high tension V orsicht! Hochspannung Preé caution! haute tension Precaucion! ó alta tensionó

Figure 2.9

Interlock box: high-tension warning label

2.2.7 Interlock Warning Labels

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

2-12

SAFETY ON THE LUXEL V-6

2-12 S AFETY ON THE L UXEL V-6 Figure 2.10 Interlock defeated warning labels: typical Luxel
2-12 S AFETY ON THE L UXEL V-6 Figure 2.10 Interlock defeated warning labels: typical Luxel
2-12 S AFETY ON THE L UXEL V-6 Figure 2.10 Interlock defeated warning labels: typical Luxel

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

LUXEL V-6 SERIES CTP 2-13

L UXEL V-6 S ERIES CTP 2-13 Figure 2.11 Interlock defeated warning labels: typical Luxel V-6
L UXEL V-6 S ERIES CTP 2-13 Figure 2.11 Interlock defeated warning labels: typical Luxel V-6
L UXEL V-6 S ERIES CTP 2-13 Figure 2.11 Interlock defeated warning labels: typical Luxel V-6

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

2-14

SAFETY ON THE LUXEL V-6

2.2.8 Safety Devices

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

Circuit breakers.

Covers and doors.

Guards.

Panel indicators.

Safety interlocks.

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

2.2.9 Unattended Equipment

Never leave equipment unattended unless in a safe condition with respect to the following hazards:

Electrical.

Mechanical.

Laser Radiation.

Chemical.

2.2.10 Dust Prevention

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

2.2.11 Plate Handling

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

LUXEL V-6 SERIES CTP 2-15

2.2.12 Electrical Safety

Regularly verify that mains supply cables are not worn or dam- aged.

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

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

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

2.2.13 Mechanical Safety

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

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

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

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

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

A) spinner

B) media handling assemblies (rollers)

C) plate pullbar

2-16

SAFETY ON THE LUXEL V-6

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

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

2.2.14 Spinner Safety

2.2.14.1 Moving Parts Safety

While the interlocks are over-ridden, a high-speed spinner mirror presents a danger for the engineer.

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

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

2.2.14.2 Acoustic Noise Safety

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

2.3 Safety Interlock System

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

2.3.1 Interlocked Covers

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

LUXEL V-6 SERIES CTP 2-17

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

1
1

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

2-18

SAFETY ON THE LUXEL V-6

2 1 Figure 2.13 Location of interlock covers: Luxel V-6 single-cassette
2
1
Figure 2.13 Location of interlock covers: Luxel V-6 single-cassette

LUXEL V-6 SERIES CTP 2-19

3
3

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

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

2.3.2 Locked Covers

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

2.3.3 Interlock Over-rides

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

2-20

SAFETY ON THE LUXEL V-6

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

ENGINE FRAME DOOR SWITCH OVERRIDE KEY
ENGINE FRAME
DOOR
SWITCH
OVERRIDE
KEY

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

LUXEL V-6 SERIES CTP 2-21

AUTOLOADER SERVICE SIDE

INTERLOCK OVERRIDE KEY INTERLOCK SWITCH
INTERLOCK
OVERRIDE
KEY
INTERLOCK
SWITCH

TO OVERRIDE:

INSERT KEY AND TWIST CLOCKWISE

TO REMOVE KEY:

TWIST ANTI-CLOCKWISE AND REMOVE

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

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

2.4 Laser Safety

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

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

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

2-22

SAFETY ON THE LUXEL V-6

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

2.4.1 Laser Precautions

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

Do not power up the platesetter with a laser disconnected.

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

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

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

2.4.2 Laser Safety Shutter

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

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

diagnostics/service/optics/laser/ldisable

LUXEL V-6 SERIES CTP 2-23

OPTICS BASE (USER END) SHUTTER OPEN CLOSED Figure 2.17 Optic base shutter
OPTICS BASE
(USER END)
SHUTTER
OPEN
CLOSED
Figure 2.17 Optic base shutter

2.4.3 Laser Safety Warnings

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

Note the following laser radiation warning:

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

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

2-24

SAFETY ON THE LUXEL V-6

instance, photodiodes. Reflected beams can also cause damage.

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

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

2.4.3.1 A DLA Room

All other personnel should be warned of the hazard by:

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

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

2.4.3.2 A DLA Curtain

Local legislation may permit the following alternative:

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

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

LUXEL V-6 SERIES CTP 2-25

LASER CLASS IIIb OPERATIONS WHEN WARNING LIGHT IS ON NO ENTRY TO UNAUTHORISED PERSONNEL
LASER CLASS IIIb OPERATIONS WHEN WARNING LIGHT IS ON NO ENTRY TO UNAUTHORISED PERSONNEL

LASER CLASS IIIb OPERATIONS

WHEN WARNING LIGHT IS ON

NO ENTRY TO UNAUTHORISED PERSONNEL

LASER CLASS 3B OPERATIONS WHEN WARNING LIGHT IS ON NO ENTRY TO UNAUTHORISED PERSONNEL

LASER CLASS 3B OPERATIONS

WHEN WARNING LIGHT IS ON

NO ENTRY TO UNAUTHORISED PERSONNEL

U.S.A.

EUROPEAN

Figure 2.18 Typical laser warning signs

2-26

SAFETY ON THE LUXEL V-6

U NPACKING AND H ANDLING This section describes how to unpack and move Luxel V-6e

UNPACKING AND HANDLING

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

3.1 Unpacking the Equipment

3-1

3.2

Handling the Equipment

3-6

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

3.1 Unpacking the Equipment

3.1.1 Consignment Check

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

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

Engine (all variants)

Autoloader (single-cassette)

Autofeeder (multi-cassette)

Trolley and Cassette

3-2

UNPACKING AND HANDLING

Stacker (if ordered)

Processor (semi- and fully-automatic)

PAT Air Filter (all variants)

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

Dimensions and weights of the packed modules for all variants is

given in the Luxel V-6 Series CTP Pre-Installation Guide.

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

3.1.2 Inspection of Boxes

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

1. Record the observations on the delivery documentation.

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

3. Record the observations on the FFEI Installation Report.

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

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

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

LUXEL V-6 SERIES CTP 3-3

TIP-N-TELL UP BLUE BEADS IN ARROW HEAD SHOWS CONTAINER WAS TIPPED OR MISHANDLED DROP-N-TELL COSTERWISE
TIP-N-TELL
UP
BLUE
BEADS
IN
ARROW
HEAD
SHOWS
CONTAINER
WAS TIPPED
OR MISHANDLED
DROP-N-TELL
COSTERWISE LTD.
16, Rabbit Row
London W8
Tel: 81-2210668

TIP-N-TELL

Figure 3.1 Mishandling indicators

3.1.3 Unpacking the Modules

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

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

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

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

2. Cut any bands securing the box.

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

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

3-4

UNPACKING AND HANDLING

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

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

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

FOAM FORK STOP BEARING FORK STOP FOAM INSERT BLOCK BLOCKS BLOCK INSERT PLAN VIEW FRONT
FOAM
FORK STOP
BEARING
FORK STOP
FOAM
INSERT
BLOCK
BLOCKS
BLOCK
INSERT
PLAN VIEW
FRONT
REMOVEABLE
FORK
FORK

FRONT BLOCK

Figure 3.2 Unpacking FFEI module boxes

LUXEL V-6 SERIES CTP 3-5

8. Remove any foam inserts around the palette.

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

CAUTION: Check that the anchor feet are fully retracted.

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

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

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

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

Table 3.1 V-6 and V-6e accessories packs

1

FireWire cable (10 m)

2

User’s Safety Guide

3

Getting Started Guide

4

Manifold blanking plate and (4-off M6 screws)

5

Luxel V-6 CTP (Application) CD

6

Luxel V-6 CTP (PCI) CD

7

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

8

Diagnostics comms cable (10 m or optional 25 m)

9

Vacuum pump (VT4.25)

10

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

11

Vacuum Nylon tube 16 mm black

12

G10 film sheet for PC next to a manual loading machine

13

Luxel CTP Product Manuals CD

3-6

UNPACKING AND HANDLING

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

14

Mains cable

15

Top height gauge/memory plate (Autoloader only)

16

Over-ride key (Autoloader only)

17

Feet seating plates (Autoloader only)

 

Table 3.2

V-6 multi-cassette support pack

1

Adaptor top

2

8-off M5 x 20 cap head screws

3

V6AF_CAN_AUTO cable

4

V6AF_EARTH cable

5

V6AF_MAINS_FEED cable

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

3.1.4 Unpacking the Processor

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

Use the supplied Installation Manual to unpack the processor.

3.2 Handling the Equipment

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

Castors are fitted to allow modules to be moved short distances

LUXEL V-6 SERIES CTP 3-7

and for manoeuvring it into its working position.

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

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

3.2.1 Using a Fork-Lift

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

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

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

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

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

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

3-8

UNPACKING AND HANDLING

I NSTALLING L UXEL E QUIPMENT AND S OFTWARE This chapter shows how to install

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

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

4.1 Start the Installation

4-1

4.2

Install the Processor

4-9

4.3

Install the Engine

4-10

4.4 Install the Autoloader (Luxel V-6)

4-17

4.5 Install the Multi-Cassette Autofeeder (MAL)

4-28

4.6 Set up the System

4-48

4.7 Install Luxel Desktop Applications and Device Driver

4-58

4.8

Installing Licence Options and Upgrades

4-59

4.1 Start the Installation

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

4-2

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

for installing the system:

socket set up to 12 mm (Metric)

600 mm spirit level

adjustable spanner up to 30 mm jaw space.

4.1.2 Pre-Install Checks

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

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

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

4.1.2.1 Check Floor Gradient

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

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

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

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

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

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

LUXEL V-6 SERIES CTP 4-3

D) Continue these measurements for the same direction.

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

F) Total the readings for each direction separately.

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

(X1) (Y) (X2)
(X1)
(Y)
(X2)

FLOOR GRADIENT RISE/FALL REQUIREMENT:

(X1) AND (X2) = LESS THAN 30 mm (Y) = LESS THAN 30 mm

Figure 4.1 Checking floor gradients: Luxel V-6

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

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

4.1.3 Remove the Module Covers

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

4-4

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

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

SL SL SL I I SL NL SL I a) V-6 FULLY-AUTOMATIC (MULTI_CASSETTE) SL
SL
SL
SL
I
I
SL
NL
SL
I
a) V-6 FULLY-AUTOMATIC (MULTI_CASSETTE)
SL
SL I b) V-6 MANUAL AND SEMI-AUTOMATIC
SL
I
b) V-6 MANUAL AND SEMI-AUTOMATIC

KEY:

SL
SL

SCREW LOCKED

NL
NL

NOT LOCKED

I
I

INTERLOCKED

SL SL I c) V-6e MANUAL AND SEMI-AUTOMATIC
SL
SL
I
c) V-6e MANUAL AND SEMI-AUTOMATIC

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

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

LUXEL V-6 SERIES CTP 4-5

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

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

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

4.1.3.1 Remove V-6 Engine Top Cover

The top cover on the V-6 engine is removed as follows:

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

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

USER SIDE SCREW TOP FIXING COVER (DOOR OPEN)
USER SIDE
SCREW
TOP
FIXING
COVER
(DOOR OPEN)

INSERTS

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

4.1.3.2 Remove V-6e Engine Top Cover (Manual)

The top cover on the V-6e manual engine is removed as follows:

4-6

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

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

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

The top cover on the V-6e semi-automatic engine, shown in Figure 4.4 on Page 4-6, is removed as follows:

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

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

TOP COVER
TOP
COVER

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

4.1.4 Heavy Lifting Operations

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

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

manoeuvre the modules into position

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

LUXEL V-6 SERIES CTP 4-7

position the vacuum pump.

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

4.1.5 Installation Sequence

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

4.1.5.1 Semi-Automatic (Luxel V-6e)

Install a semi-automatic system in the the following module order Figure 4.5 on Page 4-7 below:

(2) ENGINE

(1) PROCESSOR
(1) PROCESSOR

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

4.1.5.2 Semi-Automatic (Luxel V-6)

Install a semi-automatic system in the the following module order Figure 4.6 on Page 4-8 below:

4-8

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

(2) ENGINE (1) PROCESSOR (3) PLATEN
(2) ENGINE
(1) PROCESSOR
(3) PLATEN

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

4.1.5.3 Single-Cassette Fully-Automatic (Luxel V-6)

One Fully-Automatic only: Install a fully-automatic system in the the module order shown in Figure 4.7 on Page 4-8.

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

(2) ENGINE

(3) AUTOLOADER (1) PROCESSOR (4) TROLLEY & CASSETTE
(3) AUTOLOADER
(1) PROCESSOR
(4) TROLLEY &
CASSETTE

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

LUXEL V-6 SERIES CTP 4-9

4.1.5.4 Multi-Cassette Autofeeder (Luxel V-6)

One single-cassette only: Install a multi-cassette system in the the following module order Figure 4.8 on Page 4-9.

(4) AUTOFEEDER (2) ENGINE (5) TROLLEY & CASSETTE (1) PROCESSOR
(4) AUTOFEEDER
(2) ENGINE
(5) TROLLEY &
CASSETTE
(1) PROCESSOR

(3) AUTOLOADER

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

4.2 Install the Processor

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

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

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

1. Locate the processor in its correct working position.

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

3. Level the processor at each corner.

4-10

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

4.3 Install the Engine

4.3.1 Remove Engine Transit Fixings

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

The Engine is shipped with a set of transit fixings that MUST be removed BEFORE switching on power. Each fixing is identified by

a label colour-coded orange; all screw fixings are colour-coded green.

Remove the following transit fixings:

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

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

C) MMI console cover.

4.3.1.1 Traverse Carriage Transit Fixing

See Figure 4.9 on Page 4-11.

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

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

2. Check that the ball cage is clean and undamaged. Lay the cage on

a flat surface and check that it is straight; if it is deformed then adjust it before fitting.

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

4. From the user side: Insert the ball cage on the V-groove and slide

it under the carriage, shown in Figure 4.10 on Page 4-12, noting

the orientation. Push it towards the service end until it is up against the service end stop.

If it is difficult to slide the ball cage between the V-grooves under

the carriage then slacken the transit screws slightly.

LUXEL V-6 SERIES CTP 4-11

TRANSIT BRACKET SCREW FIXING POINTS SCREW FIXING POINT ORANGE TRANSIT SCREW
TRANSIT BRACKET
SCREW
FIXING
POINTS
SCREW
FIXING
POINT
ORANGE
TRANSIT
SCREW

Figure 4.9 Removing the traverse transit bolt

4-12

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

4-12 I NSTALLING L UXEL E QUIPMENT AND S OFTWARE CARRIAGE RAIL BALL CAGE TRAVERSE RAIL
CARRIAGE RAIL BALL CAGE TRAVERSE RAIL Figure 4.10 Fitting the ball cage
CARRIAGE
RAIL
BALL CAGE
TRAVERSE
RAIL
Figure 4.10 Fitting the ball cage

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

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

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

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

4.3.1.2 Platen Transit Fixings (V-6 Only)

Remove the transits on the four pins (lift and centre).

4.3.2

LUXEL V-6 SERIES CTP 4-13

Integrate the Processor and Engine

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

4.3.2.1 Set the Processor Height

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

See Figure 4.11 on Page 4-15.

1. Locate the processor in its correct working position.

2. Remove the processor top cover and heater cover.

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

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

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

NOTE: Do not use the engine panels for levelling.

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

6. Remove the rule.

4.3.2.2 Mate the Engine to the Processor

See Figure 4.11 on Page 4-15.

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

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

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

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INSTALLING LUXEL EQUIPMENT AND SOFTWARE

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

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

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

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

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

NOTE: Do not use the engine panels for levelling.

8. Refit the processor covers.

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

10. Connect the processor power cables.

LUXEL V-6 SERIES CTP 4-15

PLASTIC INPUT

ROLLERS RULER ENGINE PROCESSOR OUTPUT HEATER GUIDE PLATE 2 mm RUBBER NIP ROLLERS 1012 mm
ROLLERS
RULER
ENGINE
PROCESSOR
OUTPUT
HEATER
GUIDE
PLATE
2 mm
RUBBER NIP
ROLLERS
1012 mm

Figure 4.11 Levelling the engine and processor

4.3.3 Level the Engine

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

4.3.3.1 Manual System

See Figure 4.12 on Page 4-16.

1. Locate the engine in its working position.

4-16

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

4-16 I NSTALLING L UXEL E QUIPMENT AND S OFTWARE CASTOR 12 mm ANCHOR FOOT 16
CASTOR 12 mm ANCHOR FOOT 16 mm Figure 4.12 Adjusting the engine castors and feet
CASTOR
12 mm
ANCHOR
FOOT
16 mm
Figure 4.12 Adjusting the engine castors and feet

4.3.3.2 All Variants

LUXEL V-6 SERIES CTP 4-17

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

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

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

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

4. Replace any covers.

ENCODER

SCALE

TRAVERSE 600 mm DRIVE RAIL SPIRIT LEVEL
TRAVERSE
600 mm
DRIVE RAIL
SPIRIT LEVEL

Figure 4.13 Vertical levelling

4.4 Install the Autoloader (Luxel V-6)

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

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

4.4.1 Remove Autoloader Transit Fixings

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

4-18

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

DIVERTER

TRANSIT FIXING

(RIGHT) DIVERTER TRANSIT FIXING (LEFT)
(RIGHT)
DIVERTER
TRANSIT FIXING
(LEFT)

Figure 4.14 Remove the diverter transit fixings

1. Remove the top interlocked cover from the autoloader.

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

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

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

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

LUXEL V-6 SERIES CTP 4-19

NUDGER LIFT

TRANSIT FIXING

(RIGHT) NUDGER LIFT TRANSIT FIXING (LEFT)
(RIGHT)
NUDGER LIFT
TRANSIT FIXING
(LEFT)

Figure 4.15 Remove the nudger transit fixings

4.4.1.1 Remove the MLS Transit Fixings

Remove the following (see Figure 4.16 on Page 4-20):

A) Tape holding the door closed.

B) Transit screw on the M-roller assembly.

4-20

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

TRANSIT

SCREW M-ROLLER ASSEMBLY MLS COVER TAPE (BOTH ENDS) NUDGER ARM NUDGER TRANSIT FIXING NUDGER FRAME
SCREW
M-ROLLER
ASSEMBLY
MLS COVER
TAPE
(BOTH ENDS)
NUDGER
ARM
NUDGER
TRANSIT
FIXING
NUDGER
FRAME

Figure 4.16 MLS transit screw

LUXEL V-6 SERIES CTP 4-21

4.4.2 Mate the Autoloader and Engine

The autoloader and engine are mated as follows:

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

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

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

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

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

4. Check that LK1 and 2 are not fitted on MSB2 and fitted on MSB3,
4. Check that LK1 and 2 are not fitted on MSB2 and fitted on
MSB3, see Figure 4.17 on Page 4-21.
LK1
LK2

Figure 4.17 Location of LK1 and 2 on MSB2

4-22

INSTALLING LUXEL EQUIPMENT AND SOFTWARE

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

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

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

23.

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

5. Lock the four autoloader feet.

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

LOCKING

NUT 8 mm JACK BOLT
NUT
8 mm
JACK
BOLT

SEATING

PLATE

Figure 4.18 Adjust the autoloader feet

LUXEL V-6 SERIES CTP 4-23

AUTOLOADER ADAPTOR ASSEMBLY (FITTED TO ENGINE) KEYHOLE AUTOLOADER (2-OFF) M5 SCREW (5-OFF) KEYHOLE ADAPTOR
AUTOLOADER
ADAPTOR
ASSEMBLY
(FITTED TO ENGINE)
KEYHOLE
AUTOLOADER
(2-OFF)
M5 SCREW
(5-OFF)
KEYHOLE
ADAPTOR
ASSEMBLY
ADAPTOR
PLATE PIN
(2-OFF)

PIN IN SLOT CONTACTING LOWER LIP

Figure 4.19 Locate the adaptor pins and keyhole slots