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DPX 4 / Fredia User Guide

1. imaging systems DPX 4 User Guide Chapter 7 Maintenance 2 Install the EXIT ROLLERS as shown below If 4 Install the ENTRANCE GUIDE as shown below the gear at the ned of the top roller won t mesh with the mating roller pull down the PULL LEVER move the roller as need until the gears mesh and then release the PULL LEVER EXIT ROLLER NO GEAR 3 Install the ENTRANCE ROLLERS as shown below If the gear at the end of the roller won t mesh with its mating gear pull down the PULL LEVER adjust the roller until the gears mesh and then release the PULL LEVER ECRM imaging systems Chapter 7 Maintenance DPX 4 User Guide 6 Install the BACK UP ROLLER as shown below 8 Install the METERING ROLLER as shown below 9 BACK UP ROLLER 7 Turn the rack over so that the top is facing up 9 and then install the WIRE GUIDE as shown below Install the INLET GUIDE as shown below 42 ECRM imaging systems DPX 4 User Guide Chapter 7 Maintenance 10 Install the HOPPER ASSEMBLY as shown 12 Install the SUPPLY PIPE ASSEMBLY as shown below below 10 m 11 Install the TOP GUIDE as shown below E 1 1 a L Pame AS m_n i i E WE BE A N a Y hy N Ek A U i e 14 Set the rack in place in the rear bay in the DPX 4 replace the mounting nut and tighten the captive fasteners ECRM d imaging systems Chapter 7
2. k 46 Shan el a S upph qlr e enee _ e mme 46 Lubricating the Worm Gears M E E keke kek kek kek keke kek ke KK K k Kek K KA KHK HHHH KH KA KA KA KA KA KK AH HH HH HH 47 Chapter 8 Technical Specifications Chapter 9 Troubleshooting TrowbleshOoume Table zcacaicacnscarazcanntaayacoaesanaban 440044 k kik w b h nd bab sk d ba b n kb k ek eiad W bk k bb kk R 53 DID VCS ACS cek k k n wed ak NNN Ce HESA Ae hec E G n ub Ker RO Ke e Be Her beR eW b VR DEN e D Eve GOC 53 Dost r J r rrrrrhD rrrrzJr JJ ta aaa 54 imaging systems vi DPX 4 User Guide imaging systems DPX 4 User Guide Chapter I Using this Guide Chapter 1 Using this Guide This section includes the following topics Navigating this guide in Acrobat Reader page 1 Warnings and notes page 2 Printing this guide page 2 Note The instructions in this section are for Acrobat Reader v7 0 Navigating this guide in Acrobat Reader If you are using Acrobat Reader to view this guide we recommend you use the following Acrobat navigation buttons id Go to the first page of the guide Go back one page k Go forward one page bl Go to the last page of the guide g Go back to previous view Go forward to next view Fit whole page in window x Close bookmarks ECRM imaging systems Bookmarks You can use the Bookmarks window t
3. 6 Gently push the processor unit back into position 7 Turn the processor lock handle to horizontal position to lock the processor The activator temperature is regulated by means of a computer controlled heating element and must be between 20 C 68 F and 33 C 91 F WARNING Never turn on the power unless the processor unit is filled or the power plug for the heating element is removed as this may cause overheating and damage to the processor unit ECRM Ku imaging systems Chapter 7 Maintenance DPX 4 User Guide Removable Parts Activator Rack Zar x Supply Pipe Assembly _ 8 WEN li wi WW NNN Wi iyi Entrance Guide ii Tut ja ECRM imaging systems DPX 4 User Guide Chapter 7 Maintenance ACTIVATOR RACK BACKUP GEAR AT BOTH ENDS BOTTOM 35 imaging systems Chapter 7 Maintenance DPX 4 User Guide Removable Parts Stabilizer Rack 1 TTT AAVA MOVON WON EOE WO LID EF yh s PR ii A M RARER ARH At NEN NN LONG atta rolyuretnane no dear sy 3 41 Polvurethane wi ear g 1 IAN 7 r ka 2 Polyurethe ne no gear 20 ECRM imaging systems DPX 4 User Guide Chapter 7 Maintenance STABILIZER RACK FRONT 6 Inside wall left gear train side of rack 30MM TAPERED 4 WITHOUT GEAR OL O 5 gt AE 30MM WTH GEAR 25MM a S POLY WITHOUT GEAR 3 1 gt
4. Maintenance Cleaning the Activator Supply Pipe The activator supply pipe on the supply mount should be cleaned on a regular basis or whenever the drip holes in the pipe become clogged with hardened activator 1 At each end of the activator pipe pull the elbow see below out of the activator pipe 2 Remove the supply pipe assembly by sliding it toward the activator supply tube and then up and out of the two keyways See below Supply Pipe Assembly 44 DPX 4 User Guide 3 On the right side of the platesetter pop open the door remove the cover and then remove the pick and the knife wire brush that are clipped to the frame See below Cleaning Tools Using the pick remove hardened activator from the drip holes in the activator supply pipe and then use the wire brush to remove hardened activator from the interior surface of the pipe Rinse the interior of the pipe with clean water If necessary repeat steps 4 and this step to remove all traces of hardened activator from the holes and the pipe Set the pipe back in place in the supply mount assembly and plug the supply tube elbows back into the pipe Put the pick and the knife wire brush back into their clips on the frame Note As a rule the water supply pipe does not require cleaning so leave it in place imaging systems DPX 4 User Guide Replacing the Diffusion and Anti backflow Sheets The diffusion sheet and anti backflow sh
5. STABILIZER ACTNATOR array CTN ACTEN The processor should be cleaned every time the chemistry is changed The procedure is as follows 1 Drain the processor as explained on page 31 nu ii miii ana SEF if 2 Remove the rack covers Refer to the figure below In order remove 1 the inlet guide 2 the activator cover and 3 the stabilizer cover iT 7 gt Mai iyi gt Ot rr bisp Tre Sw ee ee WU re hpi ACTIVATOR Niye ya nak COVER INLET GUIDE 5 Remove the racks Pull each one out by grasping the handles at either end of the rack and then pulling it straight up and out J 6 Clean the activator and stabilizer tanks Ta i e Pour clean water into the tanks clean with Ph 3 Disconnect the two supply tubes shown neutral soap and a soft brush and rinse with below from the tee fittings clean water ECRM imaging systems 32 DPX 4 User Guide Chapter 7 Maintenance 7 Let the water run off the rack before putting it back in position 8 Finish by draining the cleaning water from the waste tank 9 Remove any chemical residue on the drain hose and hose coupling 10 Clean the rollers racks and guides in the activator and stabilizer racks Clean with a soft brush and lukewarm water Finish by rinsing the parts with clean water If you have a large wash sink at your disposal you can just set the racks down in the sink and c
6. Select the required printer from the Name pull down menu Click on the Properties button and select the Portrait orientation on the Layout tab Click on OK to return to the Print dialog Set the other options such as the page range then click on OK to print this guide or the specified pages ECRM imaging systems DPX 4 User Guide Chapter 2 Safety General Although every precaution has been made to produce a safe product we strongly recommend you comply with the following The equipment must be properly grounded when connected to electrical outlets Turn off power before connecting or disconnecting cables and before carrying out maintenance or adjustment operations Do not remove covers or shielding Do not install use the equipment close to inflam mable gases and vapors Do not make any unauthorized modifications of the equipment Wear protective gloves when handling chemistry and avoid spilling the fluids Always check that the actual media width in Media Management corresponds to the actual media being used The spinner in the platesetter cannot be started in an ambient temperature of less than 15 degrees Celsius The equipment must be protected by a circuit breaker appropriately rated for the machine imaging systems Chapter 2 Safety Laser This system is classified as a Class one I laser product that contains a Class 3B IIIb laser system This classi
7. Warnings and notes Warnings The warnings in this manual are intended to protect you from injury and or to protect the DPX 4 engine and your plates from damage Read all warnings carefully and follow any instructions they include Warnings appear in bold print like this WARNING When working with the DPX 4 system you must protect yourself from injury and protect the DPX 4 engine from damage Notes The notes in this manual give additional infor mation on using the DPX 4 system Notes appear in italics like this Note The instructions in this manual are for the DPX 4 system Printing this guide To print this guide DPX 4 User Guide In Acrobat Reader select Print from the File menu A dialog similar to the one shown below appears Printer Name Jil SA EI ala x Status Ready Type HP Laserdet 5000 Series PS Where IP_10 31 144 30 Print Range All e Current page C Pages from 1 to 44 Print Even and Odd Pages r V Comments PostScript Options Print Method Language Level 2 Y V Optimize for Speed MV Download Asian Fonts Save Printer Memory Color Managed On printer Printing Tips Properties Reverse pages Print as image Print to file Copies and Adjustments Number of copies 1 IV Collate V Shrink oversized pages to paper size Expand small pages to paper size V Auto rotate and center pages Preview j 8 504 N Units Inches Zoom 100 0 Cancel
8. Easy Maintenance and Monitoring of the Processor The processor is mounted on wheels A guide allows it to be rolled out easily for maintenance or chemistry replenishment The DotManager program controls and monitors the processor and displays real time processor status information on the PC monitor Work The DPX 4 is controlled by a Win2000 or WinXP based RIP platform The DotManager program controls the media and the processor and imaging systems Chapter 3 Introduction integrated operation with the ECRM WorkMates work program The interface between the DPX 4 and the RIP PC operates via a USB 2 0 port Chapter 3 Introduction DPX 4 User Guide i ECRM imaging systems DPX 4 User Guide Chapter 4 Media Handling Chapter 4 Media Handling Media Load System The DPX 4 has a twin compartment media load system that accommodates two plate sizes Each compartment includes an auto centering media spindle see below Its mechanism ensures precise centering of the media on the shaft every time a new roll is loaded During operation the media is automatically advanced positioned in the drum and held in place by aunique vacuum system during exposure Inserting and Mounting Media Removing the Media Roll 1 Make sure the media is unloaded Unload button on DotManager s Control Windows 2 Lift up the top cover see figure at right Twin compartment MEDIA SPINDLE 11 imaging systems
9. POLY WITH GEAR BOTTOM 37 imaging systems Chapter 7 Maintenance Installing the Stabilizer Rack Rollers and Bottom Guide Steps for installing the rollers and guide are presented below The same basic technique 1s used to install each roller and the guide First insert the spring loaded end of the roller guide into its bushing on right side of the rack Next compress the roller guide into the bushing align the opposite of the roller guide with its bushing on the left gear train side of the rack Finally gradually relax compression to seat the roller guide in the bushing When you install a roller pair use the pull lever to spread the rollers apart to get the gears to mesh The picture below shows how the 6 rollers look when in place with the rack turned upside down The GUIDE ROLLER W GEAR and the rod immedi ately above it have been cut away to clarify the view of the ENTRANCE ROLLER erie aliie NO GEAR W GEAR LEFT SIDE side with gears GUIDE ROLLER A W GEAR ENTRANCE ROLLER NO GEAR 38 DPX 4 User Guide 1 Lay the stabilizer rack on a table as shown below 2 Install the GUIDE ROLLER W GEAR Mount the end with the spring first and then end with the gear see below 3 Install the ENTRANCE ROLLER W GEAR as shown below You may need to retract the PULL LEVER to get the gears to engage gt imaging systems DPX 4 U
10. C 33 C nominal Approximately 20 min nominal settings in an 18 C environment 3 x 10 liters including water ECRM imaging systems DPX 4 User Guide Waste Tank Capacity Waste Tank Pump Rate Dip to Nip distance Activator Dip to Nip distance Stabilizer Plate Advance Speed Drying System Heaters Temperature Range Settings ECRM imaging systems Chapter amp Technical Specifications 20 liters to full sensor 30 liters full 10 liters min Approximately 390 mm Coating roller to nip 140 mm Approximately 200 mm 15 mm sec at 9 6 sec development time 2 000 Watts 30 C 50 C drying system 51 Chapter 8 Technical Specifications 22 DPX 4 User Guide imaging systems DPX 4 User Guide Chapter 9 Troubleshooting Chapter 9 Troubleshooting Troubleshooting Table PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Operator must continually Clogged dirty in line activator Replace the filter See Replac increase the flow index setting filter f to maintain plate quality ing the In line Activator Filter on page 7 46 Plate skewing scratching Dirty rollers and or guides Clean the rollers and guides See Cleaning the Processor on page 7 32 Non uniform plate develop Activator supply pipe is dirty Clean the activator supply pipe ment See Cleaning the Activator Supply Pipe on page 7 44 Online Processor General Error Loose cable connection Ensure
11. Step 2 On the left side of the processor remove the Drive Shaft Cover 3 knurled thrombi screws and the Drive Belt Cover 2 knurled thumb screws shown below Step 3 Locate the three worm gears shown below STABILIZER ii nT AR Step 4 Apply a liberal coating of 405 110 000 grease all around each of the worm gears Step 5 Replace the drive shaft cover and the drive belt cover ECRM a imaging systems Chapter 7 Maintenance 48 DPX 4 User Guide imaging systems DPX 4 User Guide Chapter 8 Technical Specifications Chapter 8 Technical Specifications In this section Media specifications page 50 e Platesetter specifications DPX 4 page 49 e Processor specifications page 50 PLATESETTER SPECIFICATIONS DPX 4 Exposure Technology Max Plate Format Min Plate Format Optional Standard Punches Custom Punch Laser Type Resolution Spinner Speed Performance Integrated Processor Replenish Capacity Waste Capacity Physical Dimensions HxWxD Weight RIP Interface User Interface Power Requirements ECRM imaging systems Internal drum 680 x 754 mm 305 x 305 mm Bacher 220 mm Plate punch Bacher 425 mm Plate punch Bacher 220 425 mm Plate punch The gripper margin is imageable Punch is in one side of the plate only Red laser diode 658 nm min 10 mW 1200 3000 dpi in steps of 1 60 000 RPM Approximately 28 full format plates per hour 2540 dpi Actuator coater wi
12. 4 Idler roller stabilizer rack 39 Imagesetter Tab 24 Inlet guide activator rack 42 43 In line activator filter 46 K Knife wire brush 44 L Laser 3 License Tab 23 Lock handle media spindle 12 Lubricating worm gears 47 M Maintenance cleaning DPX 4 29 Media inserting 11 mounting 11 Media Roll mounting new 14 removing 11 Media spindle 11 Media Tab 19 change media setup 19 Metering roller activator rack 42 P Pick cleaning 44 Platesetter Tab 17 activate standby 18 form feed 18 Magazine 1 and Magazine 2 17 message log 18 platesetter status 18 preload unload 18 start stop Sweep Mode 18 status 18 temperatures 18 Power requirements 49 Power switch 7 Preferences Tab 20 Anti Oxidant 21 online processor 20 Standby Anti Oxidant 21 Standby Processor 21 Processor 31 cleaning 32 draining 31 filling 33 tank capacities 50 Pull lever 38 41 R Replacing diffusion and anti backflow sheets 45 supply pump 46 Replacing the backup roller 45 Resolutions 49 RipManagement Tab 22 Imagesetter Tab 24 Licence Tab 23 Spool Tab 24 RIPMate starting stopping 16 DPX 4 User Guide RIPMate options CIPMate 24 Extended Workflow 23 ProofMate 23 roller 42 S Safety General 3 Safety labels 4 Service Tab 19 General 19 Pump issues 20 Setup Tab 21 LicenseKeys 22 Specifications 49 Spool Tab 24 Stabilizer replenishment 21 Stabilizer rack reassembling parts 38 removable parts 36 Supply pipe activator 44 cleaning t
13. KAKA KA KAKA KAKA KAKA KAKA 22 CO MA estes e See EN e YN E cek n e N a Dn KK 23 MSS AID E E A AEEA E AE AOE EA E EEE rn 23 PO TaD cJ J r rrprJJrrrr r er r mr m m ene E ee ere er ner acer ee rr rrr r r 24 han Mi ban p c T5rX 5TDTZTZTZZJmrr rl bg mm 24 Chapter 6 Calibration Why Is Calibration Necessary cscs siaccessesscodeseasseeedecaunsddadacsasaedacueanledectoeeedadeasadeedsedeeesuedadaceecdctedeotes 27 Chapter 7 Maintenance c NXT J Jrr ereb A E E N E E E 29 Opening the Processor Drawer and the Side Panels LE k ke 29 Pauline out the ProcossOr ssesimiceanen eS E T gt 2 2 2 gg ykkDMDNDNAEnNEEE E 30 Draining he TOCESSOL L 5 s isas4lysaano ako nyexenyk tne enAnnan ka eo TOENE 31 iv imaging systems DPX 4 User Guide Ceanna uav SJ SEN N MN re_e_ e o roarrrrrrrrrr 32 Filling the Processor Chemistry Ee eke eee eee keke ke keke K KH K HA HHH A HH HHH HH HHH K KK KA HHH HH HH WU 33 Installing the Stabilizer Rack Rollers and Bottom Guide E n 38 Installing the Activator Rack Rollers Racks and Guides eee 40 Cleans the Activator Supply Pipe ccsuisccsssdesacdnsscnnnnenstecuaraiuadesaebordabeceveueradeimabanesieneniuaeeddededsoeceales 44 Replacing the Diffusion and Anti backflow Sheets LEE e k k 45 Replacime the bek ROMCE Md Ka DM eea e a ae aAA E N ZM J MIM 45 Replacing the In line Activator Filter hh eee eee keke kek ke kek kek kek
14. all cable connections 2320 reported Display Messages The system monitors its own operation and continually displays messages in the Status and Log windows as it does The table on the next page describes some of the messages including many of particular value for troubleshooting imaging systems are tight DotManager Online FREDIA Eco File view Tools Help e 6 Platesetter Media EcoPreferences Service Status Magazine 1 Standby ead Fesd i Plate 340 Media Name aan Unload Cut Length 50 48 m Prepare Media Feed to Processor Magazine 2 Fom Feed Punch Processor Media Name Plate 754 X Expose Conveyor Start Length 1 30 m Sweep Mode Temperatures Activator 3250 C Dryer 25 50 C Platesetter Status Message Log Opening USB pipe 1 Opening USB pipe 2 Connected to device Online Command s completed 2J Chapter 9 Troubleshooting DPX 4 User Guide Display Messages INFORMATION Message Remarks Processor Busy Processing Processor is running the power up cycle or a plate is being processed Processor Busy Feeding Processor is running the power up cycle or a plate is being fed into the processor Eco Processor Standby Safe To Power Off The processor is now in standby and can be safely powered off WARNINGS Message Remarks Processor Info Refilling Activator Activator tank is being refilled automatically Processor Info
15. for safe operation of this product ECRM imaging systems DPX 4 User Guide Chapter 3 Introduction General This section describes Advanced Internal Drum Design page 7 Media Load System page 8 e Knife and Punch System page 8 The Laser and Spinner System page 8 e Optical System page 8 e Integrated Processor and Dryer page 8 e Easy Maintenance and Monitoring of the Processor page 9 Work page 9 The DPX 4 is a Computer to Polyester Plate System that produces imaged punched dried and cut to size press ready plates The DPX 4 foot print is only 1370 x 1060 mm 53 9 x 41 73 imaging systems Chapter 3 Introduction Advanced Internal Drum Design The DPX 4 uses an extruded aluminum drum to achieve extremely high precision and accuracy Power Switch The main power switch for the DPX 4 platesetter is located on the back panel as shown below Chapter 3 Introduction Media Load System I P NEDEN La H a a Le E DPX 4 has a twin compartment media load system An auto centering system ensures precise centering of new media on the shaft every time a new roll is loaded During operation the media is automatically advanced onto the drum where it is held in place by a vacuum system during exposure The two media compartments permit the DPX 4 to simultaneously hold two different media sizes Knife and Punch System The plate material is punched by a bu
16. has to be replenished in milli liter per hour beginning after the idle period Cleaning Cycle for the Activator Remover The processor has a mechanism for removing excess activator from the plates Activator residue that builds up on this mechanism hardens if it stays on the mechanism too long To prevent this from happening you can configure the processor to automatically clean the mechanism after remaining idle for a period of time Clean Idle Period Sets the length of time the processor can remain idle before the cleaning is performed The default setting in 60 minutes Note This cleaning is a one time event Once the mechanism is cleaned the system will not perform a subsequent cleaning regardless of how long the processor remains idle Idle Cleaning Time Sets the duration of the cleaning The default setting is 30 seconds Power Down Cleaning Enable Enables disables cleaning of the activator remover mechanism on power down ECRM imaging systems Chapter 5 Working with DotManager Coater Activator Coater The processor employs a mechanism for coating activator on the plates Activator residue that builds up on this mechanism hardens if it stays on the mechanism too long To prevent this from happening you can configure the processor to automatically flush the mechanism clean at regular intervals Flush Idle Sets the length of time between flushes The default setting in 10 minutes Flush Cycle Sets
17. the duration of the flushing operation The default setting is 30 seconds Flush Flow Sets the activator flow rate for the flushing operation The default setting is 200ml m Power On Volume At initial power up the processor automatically replenishes the activator and stabilizer supplies The following parameters provide for defining replenishment volumes Activator Replenish Defines the volume of the activator replenishment The default setting is 100 ml Stabilizer Replenish Defines the volume of the stabilizer replenishment The default setting is 100 ml Note Replenishment may or may not occur depending on whether the Reduced Power on cycle delay period has elapsed Setup Window The Setup window displays a series of platesetter related settings 21 Chapter 5 Working with DotManager To open the window first click on the access the Setup Window button fe DolManager Online OP BE Ele Yew Ike Hep eo 0 ee Seno Fiamaynnn Curent varmor BIHE Download Fare Measurement Uniti etic F Debug Leq Clear Logie Confgued Donge Hore Upelate Changin Configuration cnn valab HEKE anl aval ble o cnn au ninin HEEE C M vadabl y FT T mawe o Pridet Liseripe Kaji Attached Dargie i45 DIPA Preaduet Ka OO etase cret wadahe CT e a TT wese CC Opening USE pane 1 Uppers LISE per d Darrere W descr Exposure patep mode togped Li palalr q SW ha CoA
18. Chapter 4 Media Handling DPX 4 User Guide hz UPPER AND LOVER LIGHT COVERS 5 Place the media roll vertically on the floor and move the lock handle from the home position shown above to the end of the working range shown below 3 Lift the upper or in this case lower light protection cover 4 Gently lift the media roll out of its compartment by the end caps 6 Set one foot on the media end cap and pull the locking collar and the lock end cap off the shaft 7 Lift the media roll off the shaft ECRM imaging systems DPX 4 User Guide Chapter 4 Media Handling USING THE LOCK HANDLE The lock handle is a spring loaded wrench When the handle is down turning the handle loosens or tightens the collar depending on the direction of the turn When the handle is held up turning the handle changes its position but does not loosen or tighten the collar When the HANDLE IS DOWN Lock Handle Collar Adjustment Screw Locking Collar turning the handle loosens tightens the collar When the HANDLE IS HELD UP turning the handle merely changes its position Here s how to use the lock handle to remove the locking collar 1 Turn the lock handle from home position to the end of its working range See illustrations on the preceding page 2 Try to slide the locking collar off the shaft If it won t slide off e Lift up the locking handle This releases its grip on
19. DPX 4 Fredia User Guide ECRM imaging systems AQ302471 Revision 3 Preface DPX 4 User Guide Preface Copyright ECRM contact information Copyright 2009 ECRM Imaging Systems ECRM Imaging Systems All rights reserved 554 Clark Road Tewksbury MA 01876 USA DPX 4 Fredia User Guide Tel 001 978 851 0207 December 2009 Fax 001 978 851 7016 Web www ecrm com Doc No AG302471 Rev 3 This manual and the software it describes are provided under licence and may only be used or copied in accordance with the terms of that licence The information in this manual is subject to change without notice and should not be construed as a commitment by ECRM Imaging Systems ECRM Imaging Systems assumes no responsibility or liability for any errors or inaccu racies that appear in this manual All rights reserved No part of this manual may be reproduced or transmitted in any form or by any means without the prior written permission of ECRM Imaging Systems Windows is a registered trademark of Microsoft Corporation All other brand or product names are trademarks or registered trademarks of their respective companies or organizations i ECRM DPX 4 User Guide Table of Contents Preface 2 Chapter 1 Using this Guide Navigating this guide in Acrobat Reader k k keke k B lan a Per e e canny E A E NOS WINS DO UMS zwmmwmwwww w g gggggggggogwgoouoe
20. Fix Stab Repl Low The Stabilizer Replenish Tank is low Processor Busy Activator Temperature The activator temperature is more than degree below the setpoint Processor Busy Stabilizer Temperature The stabilizer temperature is less than the set point oF ECRM imaging systems DPX 4 User Guide Chapter 9 Troubleshooting ERRORS Message Remarks Processor Fail Act temp sensor error Processor Fail Stab temp sensor error Processor Fail Dryer temp sensor error Processor Fail Eco Hardware Interface error Processor Error Interlock Processor Error Activator Level Low Processor Error Stabilizer Level Low Processor Busy Waste container full Processor Error Water Level Low ECRM imaging systems An error is reported when any of the following conditions are detected The activator temperature read less than 0 5 Deg C Hardware fault The temperature was greater than 43 Deg C Overlimit e The temperature exceeded the setpoint by more than 3 degrees FW control loop failed The stabilizer temperature read less than 0 5 Deg C Hardware fault The dryer temperature read less than 0 5 Deg C Hardware fault The low level driver failed to initialize resulting error codes range from 2320 through 2324 The processor interlock has been detected result ing error code 1901 The activator tank AND the activator replenish tank are both low resulting error code 2001 The stabilizer tan
21. PS Cong ae Mareen The displays and dialogs are as follows Current Firmware version Displays the current firmware version in the platesetter Download Firmware Use this button to download or update the platesetter firmware to your plate setter The program will guide you through the download process To update your platesetter firmware first shut down RIPMate Measurement Units Click to open and choose between Metric and Imperial units Clear log Click the button to delete the dotmanager log file Debug Log Enable disable a debug log When debugging is enabled DotManager will record all information about the communication with the platesetter and processor into a plain text file This file can be consulted at Ripxxx DotManager log ZZ DPX 4 User Guide Product License Keys Attached Dongle Serial number of the USB dongle plugged in the RIP PC Configured Dongle Serial number of the USB dongle which is configured in the platesetter firmware License Keys input fields Enter the appropriate license key to activate certain extra license protected platesetter functions Update Dongle Configuration After entering the license key s click the Update Dongle Configu ration button to save the new license s in the platesetter firmware RIP Management Windows The RIP Management windows are used to set up and control the platesetter s basic operation To open a window first click on the access the
22. RIP Management Windows button and then click on the tab for the control window you want to open Setup Tab page 23 License Tab page 23 e Spool Tab page 24 Imagesetter Tab page 24 ECRM imaging systems DPX 4 User Guide b Dolanager Pea Ela Yew Tods Help e e gt e e Sene License Spool Imageseites Pip Folder Cvim Browns Automatic Status of AIF Proofer onk Disable image sether funchonalty a i crating Figtenege Thu Mow TE 1120239 2004 j r b ray Bade burian Cormected to dewce capes reep ode Goel Setup Tab Rip Folder DotManager needs to be able to find RIPMate on your hard disk so that it can send instructions and launch RIPMate when it needs to If you move RIPMate to a new folder you must enter the new path in the Rip Folder directory field by either typing it directly or using the Browse button to find it Automatic startup of RIP DotManager must run before RIPMate This enables DotManager to establish communication with RIPMate and to control the media management features Therefore when you want to start running RIPMate you must begin by running DotManager For convenience DotManager can start RIPMate automatically thereafter To activate this feature mark the Automatic Startup of RIP check box Proofer only disable platesetter functionality Disables the platesetter only features of RIPMate so that you can use it simply to drive a proof printer I
23. anager Chapter 5 Working with DotManager General DotManager is the user interface for the DPX 4 It runs as a separate application on the RIP PC and communicates with the platesetter through a USB interface Note The DPX 4 does not have a control panel The user communicates with the machine through the DotManager program DotManager is installed with the RIP from the CD The DotManager interacts with the RIPMate RIP by providing license management for the ECRM specific options starting stopping the RIP and providing device services DotManager opens with the splash screen below DotManager ECRM The splash screen remains for a few seconds then switches to the main screen shown in the next figure ECRM imaging systems DotManager Online FREDIA Eco File wiew Tools Help Platesetter Media EcoPreferences Service Status Magazine 1 Standby Load Feed C Media Name Plate 340 z Unload REW Preload ep heyin 50 48 Prepare Media Feed to Processor Magazine 2 l Punch Processor Media Name Plate 754 Conveyor Length 1 30 m Temperatures Activator 32 50 T Dryer 25 50 C Platesetter Status Message Log Opening USB pipe 1 Opening USB pipe 2 Connected to device Command s completed In this section e Menus page 15 Buttons page 16 Windows page 17 Menus DotManager has four pull down menus File menu View menu e To
24. and the line leading out of the filter 3 Unplug the clamped lines from the old filter and then plug the lines into the new filter 4 Remove the clamps 5 Roll the processor back into the platesetter Replacing a Supply Pump Note Wear protective gloves during this operation Also you will need 2 small open jaw clamps ECRM HB3247RH and either a rag sponge or small pan 46 DPX 4 User Guide 1 Pull out the processor and locate the activator and water supply pumps They are at the back of the processor on the right side see below Activator and Cleaning Water Pumps so 2 Insert open jaw clamps over the input and output hoses of the pump to be changed see the next figure 3 Set the rag sponge or pan on the frame to catch fluid dribble that will occur when you perform the next step 4 Disconnect the input and output fittings lines from the pump imaging systems DPX 4 User Guide Chapter 7 Maintenance 5 Turn the pump counterclockwise and remove it from the processor 6 Install the new pump 7 Connect the input and output fittings lines to the pump 8 Remove the clamps and the rag sponge or pan 9 Roll the processor back into the platesetter Lubricating the Worm Gears The worm gears for the drive mechanism should be lubricated every 12 months The recommended lubricant is ECRM P N 405 110 000 Step 1 Power down the platesetter and pull out the processor
25. andle which is positioned horizontally by the cable chain Be careful to avoid spilling when locked see below fluids Note The processor unit is supported by rails while in position and by wheels when pulled out 30 ECRM imaging systems DPX 4 User Guide Chapter 7 Maintenance Draining the Processor 4 Locate the activator and stabilizer tank drain valves show below They are the left The chemistry must be drained from the waste side of the processor stabilizer and activator tanks in order to clean the tanks or replace the chemistry 5 Open both valves Turn both valves to the horizontal OPEN position as shown below 1 Pull out the processor as explained on The chemicals in the activator and stabilizer page 30 and locate the outlet shown below tanks will drain into the waste tank 2 ACT ATOR STAF _IZER Mi IN lea l 2 Push the drain hose into the outlet until it locks 3 Drain the waste tank Press and hold the drain pump switch to activate the waste pump Release the switch when the waste tank is Note You should clean the activator and stabi empty lizer tanks prior to re filling the chemistry For details refer to Cleaning the Processor on page 7 32 31 imaging systems DPX 4 User Guide Chapter 7 Maintenance Cleaning the Processor 4 Remove the nuts and loosen the captive fasteners that secure the racks to the processor chassis see below
26. bwxrxxxzyxni VY UAT rab bl _ _ r_eaer r We ooo l b b b r J ea_a as zh rrr ll e INOUE Spacer eeeo rr Pprpr IDIrIr rrZZZZevv r wX wX wa ra aaw a s wszWzW 2QQoo Printing miS NS messene i _c_ a b m pp p pp mu Chapter 2 Safety MTN A E eset sa A E T E AEE N N E E E A A N E E E EE E NA S E T J EE OR Reg latory Information s i Ki4 44445 54551152555445154555 ka b n ka h k bawa WERAN Aa AN R eden a WA S bak bl l W da Be d bal ka b n nil senan di 2E S BNN SIS N i i MH HMI MD a E ENE BEEENEJNIEEEEHM EBMEHEHEHEEEE Em BIC Uy TEADCIS PNM pJ E r Chapter 3 Introduction o ct rrrr A O T tence renee A I E A A E E Advanced Internal Drum Design siecsaccnansaarncnienadcatsenanaceasaenphedenssunasedeouseoonavensvensneestasesataquienensvensesesaadss Sa n wann VT E N N IE N E E IDI E E A EE E A Nedic Eoad S D e e a__ _ _ aeeeeeaa E Knife and Punch Syste rr a iei The Laser and Spinner Systemi cecdcssnacnancoasacensdsessxcearnilensaansbsdenssionesaceosmemonaceessecauasensseanbasenistoatsodanmtensanes wc bu E tt S E rrr br Genes Integrated Processor and Dryer praca A4 ssy ys5saerenea anened b d l ndan a duayen K sedukdan bdb naka nianen kino b e ban ok mb eb H ek Easy Maintenance and Monitoring of the Processor M A keke eke k kek z j ezwzeaerr j acts adecenne astannast
27. cified in the input gives that same tone in the output so that a curve comparing input and output is a straight line In four color work even small deviations from a linear curve can cause significant errors in the colors produced for example changes in color balance and contrast loss of brightness and loss of highlight or shadow detail Even if the platesetter is very accurate the output will still be affected by gt et u c Q S wae D 600 Chapter 6 Calibration the type and brand of media used so calibration should be regularly checked Because of the way DPX 4 moderates its exposures it is recommended that you sweep from 200 to 1200 at steps of 200 As illustrated below the light intensity response is notched at intervals of 200 and to achieve optimum dynamic range you should use a setting near the top of one of the notches By creating a sweep in steps of 200 that starts at 200 you will be testing at the top of each notch Calibration is described in the RIP user documen tation 800 1000 1200 Exposure Setting Light response of DPX 4 exposure settings ECRM imaging systems 27 Chapter 6 Calibration 28 DPX 4 User Guide ECRM imaging systems DPX 4 User Guide Chapter 7 Maintenance General You must keep the processor clean to obtain high quality output As the media passes through chemistry it inevi tably leaves residue on the rollers in the
28. eet on the activator coater assembly see below should be replaced every 12 months 1 2 2 Pull out the processor Remove the activator tank cover Remove the activator coater assembly Refer to Installing the Activator Rack Rollers Racks and Guides on page 7 40 Remove the old diffusion and anti backflow sheets and replace with the new Replace the activator coater assembly Refer to Installing the Activator Rack Rollers Racks and Guides on page 7 40 Replace the activator tank cover ACTIVATOR RACK U FAH imaging systems Chapter 7 Maintenance Replacing the Backup Roller The activator rack backup roller see below should be replaced every 12 months 1 2 3 Pull out the processor Remove the activator tank cover Remove the backup roller Refer to Installing the Activator Rack Rollers Racks and Guides on page 7 40 Install the new backup roller Refer to Installing the Activator Rack Rollers Racks and Guides on page 7 40 Replace the activator tank cover 45 Chapter 7 Maintenance Replacing the In line Activator Filter The in line activator filter is located at the back of the processor unit see below The filter should be replaced every 12 months A F i i ith Replace the filter as follows 1 Power down the platesetter and pull out the processor 2 Insert an open jaw hose clamps over the line leading into filter
29. ences Tab page 20 Platesetter Tab The Platesetter Tab pertains to the primary functions of the platesetter DolManager Online FREMA Feo Fie View os Help e 008 Pirania Meda EcoPreteences Servae Magarne i Media Mame Five 40 Length 04a m Magar 2 F Herdis Hari Pise r Lergh 1m Temperaire Adras 20 T Dya aco t Fisterelle Malut Mersiye Log Openg LUSE pips i g Opening USE poe 2 k i Corrada bo denice Commande completed Canina completed Magazine I and Magazine 2 These sections display the available media compartment s If your platesetter is not equipped with the extra optional compartment Magazine 2 compartment will be greyed 17 Chapter 5 Working with DotManager Preload Unload When a media roll has been inserted in the media compartment click the Preload button to advance the media into the feed system When the media is loaded the button text changes to Unload and the button is then used for pulling the media out of the feed system e g in case of replacement Form Feed Click the Form Feed button to advance the media 68 cm maximum exposable film length Start Stop Sweep Mode Click this toggle button to activate or deactivate the Exposure Sweep mode The Exposure Sweep Mode provides for multiple RIP jobs to be exposed on one plate The plate setter automatically feeds the plate out when it is full or when the RIP does not supply new j
30. er Temp 45 JE Stabilizer Replenish Rate 5 l r Daran REK Stabilizer Replenish 100 mi Cleaning Cycle Coater Anti 0x Clean Idle Period B min Flush Idle fio a ae Replacement 150 mil hr Idle Cleaning Time 3 sec Flush Cycle 130 sec Stabilizer 50 mi hr V Power Down Cleaning Enable Flush Flow 1200 mi min Replacement Platesetter Status Message Log Opening USB pipe 1 Opening USB pipe 2 Command s completed Processing Activator Time Specifies the time in seconds the activator is applied to the media Activator Replenishment Rate Specifies the volume of activator fluid that has to be replenished in milliliter per square meter of developed plate Stabilizer Replenishment Rate Specifies the volume of stabilizer fluid that has to be replen ished in milliliter per square meter of developed plate Dryer Temperature Specifies the temperature of the dryer air in centigrade C ECRM imaging systems DPX 4 User Guide Activator Temperature Specifies the temperature of the activator fluid in centigrade C Flow Rate Index Sets the activator flow rate The default setting is 7 The higher the setting number the higher the flow rate Anti Oxidant Activator Replacement Specities the volume of activator fluid that has to be replenished in milli liter per hour beginning after the idle period Stabilizer Replacement Specifies the volume of stabilizer fluid that
31. f you are using RIPMate only to drive a proof printer possibly using the ProofMate option then you should mark this check box to ECRM imaging systems Chapter 5 Working with DotManager prevent RIPMate from generating an error message when it does not find an platesetter attached to your computer License Tab t DolManager DEXA Ele Yew Te Help 880z ese Setup Liete Spot Plotesester Secump Code 21706 r Dl lane k t E erke Winki FiowlMale Color Proofing System CPM CIPS Opin p ra USE pape Li peran LISE per 1 Opening LISE pine 2 Corrected to dewce Upda SW hike Epit The License tab enables the ECRM specific WorkMates options by entering the appropriate password Note This tab is not available if WorkMates Administrator is installed These options are Extended Workflow The Extended Workflow option provides extra support for larger multi user installations It adds RipSpool a dedicated input plug in Note For RIPMate 7 land higher this option is no longer license protected ProofMate The ProofMate proofing option lets you use any low or high end printer or plotter as a proofing device The only thing you need is a standard Windows printer driver With ProofMate any of thousands of printers can be used for proofing at the cost of just one printer driver 23 Chapter 5 Working with DotManager ProofMate allows simultaneous output to a proofer and to a
32. fication means that the operator is exposed to no hazardous laser light during operation and maintenance The laser itself however is a Class 3B IIIb laser device and it emits visible laser light which is considered hazardous by FDA published limits When the panels are removed an interlock system automatically switches off the laser and optics unit to insure against the risk of radiation IMPORTANT WARNING Modifications to the machine or performance of procedures other than those specified in this guide may result in hazardous laser light exposure Regulatory Information Electromagnetic Emissions DOC Canada The Canadian Department of Communications requires compliance with the Radio Interference Regulations ICES 003 This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regula tions of the Canadian Department of Communica tions Chapter 2 Safety EMC Directive Europe Complies with EN 55011 1998 This is a Class A product In a domestic environment this product may cause radio inter ference 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 state ments are required by the FCC Changes or modifications to this unit not expressly approved by the party
33. his symbol and components behind these panels may be hot Observe caution when working in these areas Attention symbol Refer to the appropriate section of the User Guide for safe operation in this area Chapter 2 Safety DPX 4 User Guide Processor chemistry warning Fuse identification Fuses must be replaced by components with identical voltage and current ratings Momentary switch Used to identify switches that are activated only when pressed Protective earth Identifies the point where protective earth is attached to the machine chassis Protective earth should only be disconnected by trained service personnel Chassis ground Identifies attachment points for chassis ground for electrical safety These attachments must be maintained for safe operation of the product Rotational hazard Wait 20 seconds before access to any area marked with this symbol ECRM Incorporated A CE Certification label 554 Clark Road k m Tewksbury MA USA zk Identifies machine model number ece Gee XAIN Sea oe Sch o serial number and date of SERIAL NUMBER Merike be KAUDE ASONI UOO DEAD DEA j ifi e pa ZE manufacture Also identifies the RATING r operating voltage frequency Ths Class A Goltal apparatus comptes with Canadian ICE 003 yeh yewe BB replace only ATTENTION Refer to the user guide A current user replaceable fuse if equipped and certifications with fuse of the same voltage and rating
34. ilt in punch system exposed and cut to size This gives a precise and even registration from plate to plate and ensures minimum mounting time and easy registering of the plate on the press The DPX 4 comes with a Bacher 425 mm punch as standard It can be field upgraded with a Bacher 220 mm as well as Komori 550 mm custom punch DPX 4 User Guide The Laser and Spinner System The DPX 4 uses fiber optic cables to transmit the dot directly into the optics and high speed spinner Optical System The optical system supports resolutions from 1000 to 3000 dpi in steps that insure the correct spot size and laser intensity for the selected resolution as well as automatic focus which ensures the optimized spot on the plate producing high quality four color print Integrated Processor and Dryer The built in processor includes an activator unit a stabilizer unit and a dryer There is a temperature control for the activator tank Both tanks have sensors for controlling the chemistry level and i Da Note Covers racks and gu des have been Hi Jae removed to show interior parts p i imaging systems DPX 4 User Guide active replenishment to ensure the correct level of new chemistry in the tanks and to achieve precise activation of the polyester plate A 30 liter waste container collects excess chemistry and alerts the user when full A drain pump provides for emptying the waste container without draining the chemistry
35. k AND the stabilizer replenish tank are both low resulting error code 2003 The waste tank is full and must be emptied The water supply tank is empty JJ Chapter 9 Troubleshooting 56 DPX 4 User Guide ECRM imaging systems DPX 4 User Guide Index A Acrobat Reader bookmarks 1 printing this guide 2 using hot links 1 Activator automatic removal of 21 temperature 33 Activator filter replacing 46 Activator pipe 44 Activator rack reassembling 40 removable parts 34 Activator supply pipe 44 Anti backflow sheet 45 B Backup roller activator rack 42 Backup roller replacing 45 Bottom guide stabilizer rack 40 C Calibration 27 Cleaning activator supply pipe 44 processor 32 tanks 32 Cleaning pick 44 D Diffusion and Anti backflow sheets replacing 45 Diffusion sheet 45 Doctor blade activator rack 41 DotManager 9 15 start before RIPMate 23 Toolbar buttons 16 DotManager Menus File menu 16 Help menu 16 Tools menu 16 View menu 16 DPX 4 functionality 7 ECRM imaging systems integrated processor and dryer 8 internal drum design 7 knife and punch system 8 laser and spinner system 8 media load system 8 optical system 8 workflow 9 Drain valves 31 Draining tanks 33 E Entrance guide activator rack 41 Exposure sweep 27 F Filling tanks 33 G Grease worm gear 47 H Hopper assembly activator rack 43 Hyperterminal 16 17 I Identification label illustration of 4 location of
36. ked RIPMate will move all jobs requesting out put to the empty cassette into the Held Queue However if the Smart Cassette check box is marked RIPMate will output to the other cassette provided it contains the correct media Jobs requesting the other cassette will be processed as usual Maximum Data Rate The first time you run RIPMate this field will be set to zero RIPMate will then test your system to find out how fast data can be sent to the platesetter If you are having frequent problems with pages caught ups you may need to set this field back to zero so that RIPMate can recalculate a reasonable rate Otherwise you should never change the value of this field Safety Factor The safety factor forces RIPMate to assume communication will be slightly slower than the value found for Maximum Data Rate A safety factor of 5 should be sufficient but if recalculating the Maximum Data Rate as suggested above does not help reduce page caught ups try to raise this value slightly Stop on printer caught ups When the RIP is unable to provide the platesetter with data at the correct speed due for example to excessive loads on the processor or network the output will be inter rupted In this case the platesetter must stop output This check box determines what RIPMate will do in the event of a caught up imaging systems Chapter 5 Working with DotManager If this check box is marked and the Retry on printer ca
37. lean with the rollers guides and racks still in place in the rack However to achieve optimal results we recommend cleaning the activator and stabilizer racks as follows Remove all the rollers racks and guides from the racks Thoroughly clean and rinse the gear trains inside the racks Thoroughly clean and rinse the individual rollers racks and guides outside the rack Clean the activator supply pipe as explained in The procedure for cleaning the activator supply pipe is as follows on page 7 43 e Place the cleaned parts back into place in the rack The next four pages show the removable parts and how they are arranged in the activator and stabi lizer racks Instructions for replacing the removable parts follow the illustrations Filling the Processor Chemistry 1 Clean the processor as explained in the preceding section 2 Turn the drain valves to the vertical CLOSED position as shown below vi ACT ATOR STAB _IZER So es 3 Add new chemicals 1 3 liters of Activator and 5 8 liters of Stabilizer IMPORTANT Avoid splashing stabilizer into the activator tank Even a small amount of stabilizer may damage the activator Note To minimize chemistry waste do not attempt to fill tanks to capacity The processor will automatically refill the remaining required quantity upon power up 4 Replace the activator and stabilizer racks 5 Replace rack covers and inlet guide
38. ny other output device such as an platesetter While you are sending one job to the proofer you can be sending another job to the platesetter thus greatly improving your output productivity ProofMate makes use of industry standard ICC profiles to provide precise color reproduction and final press color emulation CIPMate CIP3 files are used to link printing and post printing processes closer to the prepress phase With the CIPMate option RIPMate generates CIP3 files on the fly as the platesetter is driven using exactly the same screened data This means that the PostScript job only has to be processed once compared with systems that use a separate output driver for CIP3 Thus only half as much time is required and the cost and inconve nience of maintaining a duplicate CIP3 setup for each platesetter setup is avoided Spool Tab The Spool tab displays information about spooler settings b DolManager UFA Ele Yew Ies Help e ese Setup Licem Spool imageseites Network Spool Pobder vis Windowi NTH JES pes Biren Wwlewan Printer Creer E G DPH pod v0 rating Figtenege Thu Mow 10 110479 2004 Erabilia Bade burri Corrected to dewce Epiha peee nde dogg 24 DPX 4 User Guide Network Spool Folder Enter the complete path for the folder to use for spooling or use the Browse button for locating the folder Windows Printer Driver Click to open the drop down list box and
39. o quickly navigate to a specific chapter or section of this manual If the bookmarks are not visible click on the Bookmarks tab see below to display them Z Adobe Acrobat DPX4UserGuide pdf File Edit Document Tools Yiew Window Help Ga aA B l4 4 dD di VA E BE BE BS i amp Bookmark r Table of Contents _ Chapter 1 Using this guide _ Chapter 2 Introduction L Chapter 3 Safety Chapter 4 Media Handling L Chapter 5 Working with DotManager _ Chapter 6 Maintenance _ Chapter 7 Calibration _ Chapter 8 Technical Specifications Index E Signatures Comments Thumbnails Bookmarks Click on a link to move to the relevant chapter Click on a link to view the sub sections within a chapter Using hot links You can use Acrobat Reader s hot links to move quickly to the section you want when you place the mouse cursor over a hot link it turns into a hand icon There are three types of hot link e On the Contents page click on the entry to take you to the relevant section Chapter I Using this Guide Cross references you will find these throughout the manual for example refer to Printing this guide on page 1 2 for instructions Click on the section reference to take you to the relevant page On the Index page click on the index entry to take you to the relevant page
40. obs within 15 seconds from the last completed job See also Calibration in the RIPMate User Manual Activate Standby Toggles the system s operating mode Click Standby to switch the platesetter to an energy saving shut down mode that turns off motors pumps and other electrical devices Notes 1 The processor automatically flushes the activator coater and cleans the activator remover mechanism before shutting down If the Auxiliary Thermal Control hardware is installed the processor turns on the drum heater and stabilizer heater as necessary to bring the internal temperature up to 18 C 2 The processor automatically flushes the activator coater at time 0 00 i e when the processor s clock turns over to start a new 24 hour cycle 18 DPX 4 User Guide 3 If the Auxiliary Thermal Control hardware is installed the processor turns on the drum heater if the internal temperature is less than 18 C Click Activate to switch the platesetter back to a normal operating mode Status The Status section includes a number of status lamps for Load Unload Prepare Media Punch Expose Feed Cut Feed to Processor Processor and Conveyor activities in the processor Some signals from the lamps are accompanied by an additional message in the activity window below the lamps Temperatures Displays the current temperature of the Activator and the Dryer Also displays the stabilizer temperature if the Auxiliary The
41. ols menu Help menu DotManager File view Tools Help e Platesetter Media EcoPreferences Service his 15 Chapter 5 Working with DotManager File menu DotManager File View Tools Help e Save Changes Ctril 5 3 Exit Ctrl E Save Changes Click to save any changes made to the current setup Exit Click to exit the DotManager application View menu gt Dothlanager File View Tools Help g t Platesetter Ctrl F e Setup Ctrl T gz Rip Management Ctrl ivl Platesetter Click to view Platesetter tab Setup Click to view Setup tab Rip Management Click to view Rip Management tab Tools menu DothManager File View Tools Help s f ETA Start RipMate Ctr R e Stop RioMate Ctrl F E Start Hyperterminal Ctrl H 16 DPX 4 User Guide Start RIPMate Click to start the RIPMate appli cation or WorkMates Admin if PrintMate is installed Stop RIPMate Click to stop the RIPMate appli cation or WorkMates Admin if PrintMate is installed Start Hyperterminal Click to start the hyperter minal communication application used for debugging purposes Help menu DotManager File View Tools Help E J 8 Online Help F1 A About DotManager CTRL A Online Help Click to view the Online Help on screen About DotManager Opens a window displaying the current version of DotManager Buttons Addi
42. ools 44 water 44 Supply pipe assembly activator rack 43 Supply pump replacing 46 Switch drain pump 31 main power 7 T Tanks cleaning 32 draining 33 filling 33 Temperature operating 50 warm up time 50 working activator 50 Throughput 49 Toolbar buttons DotManager 16 Tools menu start Hyperterminal 16 ECRM imaging systems DPX 4 User Guide start RIPMate 16 stop RIPMate 16 Top guide activator rack 43 U Using this guide Notes 2 Warnings 2 V Valves drain 31 W Waste tank capacity 9 Water pipe 44 Wire guide activator rack 42 WorkMates options 23 Worm gears 47 ECRM imaging systems
43. processor racks For that reason any part of the processor unit which is passed by the media should be cleaned at least once a week or at regular intervals the processor should be cleaned at each change of chemistry any chemical residue on the drain hose and hose coupling should be removed The punch waste container located behind the left hand side door see below should be emptied at regular intervals The transparent part of the container can be unscrewed by turning it counter clockwise imaging systems Chapter 7 Maintenance Opening the Processor Drawer and the Side Panels Whenever the processor is drawer pulled out or a side panel is opened the interlock system halts operations and switches off the laser and optics unit When the drawer or side panel is closed the laser and optics unit are turned back on but the operations that were halted may or may not resume depending on their state when they were halted To ensure operations close and open in a orderly manner we recommend you power down the DPX 4 before pulling out the processor drawer or opening either side panel 29 Chapter 7 Maintenance DPX 4 User Guide Pulling out the Processor 3 To unlock the processor turn the lock handle to vertical position as shown below 1 Press on the area shown below to open the Cover 2 Pull out the cover and locate the PROC Cesk 4 Pull out the processor unit as far as permitted lock h
44. product conforms to all applicable provisions of Federal Regulations 21 CFR Chapter 1 Subchapter J Section 1040 10 This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause 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 ATTENTION Refer to the user guide for safe operation of this product fo N13777 ECRM imaging systems DPX 4 User Guide imaging systems Chapter 2 Safety Laser Hazard interlocked Identifies interlocks used for laser safety Hazardous laser radiation may be present when interlocks are defeated Laser Hazard general Identifies areas of machine where hazardous laser radiation may be present when interlocks are defeated Pinch shear hazard Identifies areas with moving mechanical parts where a pinch or shear hazard exists Avoid contact with these areas when machine is in operation Entanglement hazard Identifies areas with moving mechanical parts where an entanglement hazard exists Avoid contact with these areas when machine is in operation Electrical Hazard High voltage is present behind panels marked with this symbol These panels should only be removed by trained service personnel Hot surface warning Panels marked with t
45. rack until it is completely full Note These functions are performed automati cally when the tank level is low Add Volume Activator Add the indicated volume to the activator rack Stabilizer Add the indicated volume to the stabi lizer rack I O Test button Opens the service password protected I O Test window This I O Test window communicates with the relevant subsystems in the platesetter or processor and is meant for service personnel only Supply Pump Service This section includes two indicators that turn red when it is time to replace the activator pump and or the cleaning pump Every 25 000 plates for the activator pump every 50 000 plates for the cleaning pump After you change either pump press the Done button to reset the pump s plate counter to zero 0 Note When pump service is required you will be notified when you start of Dot Manager 20 DPX 4 User Guide Pump replacement instructions are presented in Replacing the In line Activator Filter on page 46 EcoPreferences Tab The EcoPreferences window displays values that are derived directly from the platesetter processor DotManager Online FREDIA Eco File View Tools Help e 6 00O Platesetter Media EcoPreferences Service Processing Power On Volume Activator Time 96 sec Activator Replenish Rate 5 miz Activates Repleni h foo Flow Rate 7 Index Activator Temp 33 Dry
46. 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 DPX 4 User Guide frequency energy and if not installed and used in accordance with the instruction guide may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his or her own expense Compliance with applicable regulations depends on the use of shielded cables which the user may be responsible for procuring Identification and Certification Label ratings plate The identification and certification label shown below is attached to the cover of the platesetter unit near the power entry receptacle Safety Labels A variety of safety labels are located throughout the DPX 4 to alert users and service personnel to potentially hazardous areas of the machine The safety labels are shown and explained on the next two pages ECRM Incorporated 554 Clark Road Tewksbury MA USA MODEL NUMBER SERIAL NUMBER MANUFACTURED RATING CLASS 1 LASER PRODUCT This
47. rmal Control hardware is installed Platesetter Status The traffic light indicates the current state of the platesetter at all times and responds to the color indicators in the Status section Red Error Orange Warning Green OK Message Log The Message Log window next to the traffic light displays general messages relating to the data connection between the DotManager and the platesetter ECRM imaging systems DPX 4 User Guide Media Tab The Media window displays a list of cassettes with information about what media type 1s loaded in the cassette length of remaining media and media thickness DolManager Online FHROLA Feo Ele Yew Took Help j e Pianepettes Mada Eerie Semiti p Detali 7 Expose Punch Zora Name Pise Eb wak i rem Thickness xu BR Lipera n LISE per 1 Opening LISE pine 2 Corrected to d wc Lipdalr SW ha Wap It is possible to create new cassettes and edit existing cassettes Media Drop Down list Displays the list of media configured for the platesetter Maximum 16 different media can be configured Name Enter a name for the new media as you want it to appear in the drop down list Width Enter the width mm of the new media Thickness Enter the thickness mm of the new media Expose Punch Zone Click the check box to choose to use the punch zone for exposure The quality of exposure in this area cannot be g
48. saxtesmatyessanree aeceeceresnnadassewaosasasesoseeacs imaging systems DPX 4 User Guide Chapter 4 Media Handling Media B DIN DMMN nNna_E nn E a NN DRMDMMDMMMMMMDMDMuIaEnnNnNnNnznRzRMJJJMM Z avA 1 Inserting and Mounting Media lisan bayek eksa yek eel bara dey kra ka ke kun henda h kekan kb Ar ke k salk 11 Remo vio Tne Media ROM usne inye neh iseniana neba neken eb be en ceceb benuheye Nabeee seva xa enan sad a n 11 Mounting a New Media Roll MM eke keke ke keke KEKE KEK KEKE KAKE KA 14 Chapter 5 Working with DotManager KworrDrDrtcvv gvvo w r wX W X9 m mr rmramv 15 MOU OOOOOew ewe0BbbSe Srbbbbbbbbn 15 Pilan sal SP ND cee orate eoeDoogbBBEEE KK BEE bd E H5 RPIJIMJMMMM 16 NIG Wy ANIC TID 222 o rrr aopo o o ya 16 ib ban abg mm m ee 16 Vee WTA cal AE E E ATO E O AAEE rde 16 ilr oaae E AE ee E EA E O AE AE AE 16 WOON aE E E E E E E sexs 17 uman WY TOS cies crea ites cect EE EE cinco E Sac ee assess EE 17 PAU SCT i E E E O E ET E 17 Lu TT I DrrDwe _er e e pp _rr r e Emmn 19 wusile 2Q bO l JZgBb b b eBn K K B e K K K K KFKEF EER EHHH HH EOE 19 COP Ge cana NE Y eooDDDDB lr HH HNHNHEHHNHREEE JN 20 wu NALV N V N Nwe jp r rmllrlrlhr r o _mrmrm a pp myx 21 Prodact Cion e a See e e _a err 22 RIP Management Windows keke eee kek kek keke k Kek keke k Kek K K
49. select the appropriate Windows printer driver installed on the RIP PC Imagesetter Tab DolManaqer Psa Ele Yew Tele Hele e e 80 Setup License Spool Imagerener r inn on page emaa Sap on mezlia nul Speed Husam m Di abin Alter D Salely Fada E Slop On ria CRA upre fe Fety on printer caught ue ar Li crating Pigtienege Thu Mow 10 1120239 2004 j r b ray Bade burriane Corrected to dence Ezpazarea zana mode g ran Stop on page errors This check box determines how RIPMate will react to a page that contains errors such as incorrect margins or corruption If this check box is marked all further output will be disabled from RIPMate until it is explicitly re enabled via the check box in the RIPMate Output Controller Monitor window If this check box is unmarked all pages with errors will be moved to the Held Queue in the RIPMate Output Controller Monitor window Other jobs will continue to print Stop on media out This check box applies only to platesetters that have more than one input cassette like the DotMate 5000 It controls what RIPMate will do if one of the cassettes runs out of media ECRM imaging systems DPX 4 User Guide If this check box is marked all further output will be disabled from RIPMate until the cassette is refilled and output it is explicitly reenabled via the check box in the RIPMate Output Controller Monitor window If this check box 1s unmar
50. ser Guide Chapter 7 Maintenance 4 Install the ENTRANCE ROLLER WITHOUT 6 Install the EXIT ROLLER W GEAR as shown GEAR as shown below below 5 Turn the assembly over and then install the rA TAPERED EXIT ROLLER as shown below Pg LX A 3 a jj DAT ROALLER NO GEAR ECRM T imaging systems Chapter 7 Maintenance 8 Install the BOTTOM GUIDE as shown below 9 Flip over the rack set it in place in the front bay in the DPX 4 replace the mounting nuts and tighten the captive fasteners 10 Snap the left and right roller pivots onto the tie bar set the scrub roller into the roller pivots see below and then lower the pivot rollers and scrub roller 40 DPX 4 User Guide Installing the Activator Rack Rollers Racks and Guides Steps for installing the rollers and guide are presented below The same basic technique is used to install each roller and the guide First insert the spring loaded end of the roller guide into its bushing on right side of the rack Next compress the roller guide into the bushing align the opposite of the roller guide with its bushing on the left gear train side of the rack Finally gradually relax compression to seat the roller guide in the bushing When you install a roller pair use the pull lever to spread the rollers apart to get the gears to mesh 1 Lay the activator rack on a table with the bottom facing up as shown below
51. th stabilizer bath Min 2 full size rolls of material Min stabilizer and actuator tank contents full replenish capacity Approximately 1 100 x 1 300 x 1 050 mm Approximately 500 kg USB 2 0 DotManager software on the RIP PC 220 240 Volt 50 60 Hz 16 A 49 Chapter 8 Technical Specifications Working Environment Temperature Max Temperature Change Installation Requirements MEDIA SPECIFICATIONS Media Media Type Thickness Core Size Media Width Large Media Width Medium Output Tray Capacity DPX 4 User Guide 40 70 RH non condensing 18 25 degrees C 2 degrees C hour 1 degree C hour 80 cm wide door 2 media rolls 2 is optional DotPrint Mitsubishi Silver Digiplate with polyester base material 0 2 mm 8 mill FR FRM on media widths from 305 750 mm 6 152 4 mm Specification 1620 305 754 mm 305 550 mm 40 maximum format plates 0 2 mm media PROCESSOR SPECIFICATIONS Tank Capacity Activator Tank Capacity Stabilizer Activator Coating Rate ml m2 Maximum Replenishment Refill Rate Activator and Stabilizer Stabilizer Circulation Rate Heater for Chemicals Activator Temperature Control Warm up Time Replenishment Containers 50 Approximately 1 3 liters Approximately 5 8 liters 0 33 ml m nominal 200 ml min 3 5 liters min Heating element activator 150 watt cartridge Heating element stabilizer 300 watt in line Auxiliary Thermal Control hardware only 25 40
52. the collar adjustment screw e Keeping the handle raised move it to the beginning of the working range shown on the preceding page e Release the handle so that it springs back down This restores handle s grip on the collar adjustment screw 3 Turn the handle approximately 180 to the end of its working range see figure on preceding page 4 Repeat steps 2 and 3 until you can slide the collar off the shaft Reverse the actions described above to replace the locking collar ECRM imaging systems 13 Chapter 4 Media Handling Mounting a New Media Roll 1 14 Slide the media onto the shaft and make sure it fits tightly against the media end cap Push the lock end cap onto the shaft Note that the media roll is automatically centered on the shaft Slide the locking collar onto the media shaft and then up against the lock end cap Lock the collar in place Refer to the Using the Lock Handle on the preceding page Place the shaft with the media roll in the compartment DPX 4 User Guide 6 Carefully remove the tape from the media and advance the roll towards the input edge Note Be sure to completely remove all the tape from the new media roll Tape or tape remnants left on the media could damage the inside of the drum in time 7 Press the Preload button to advance the media 8 Close the light protection cover imaging systems DPX 4 User Guide Chapter 5 Working with DotM
53. tionally DotManager has seven buttons for accessing various control and set up windows starting stopping RIPMate or WorkMates Admin if WorkMates is installed starting the Hyperter minal quitting DotManager and saving changes left to right DotManager Online FREDIA Eco File View Too ECRM imaging systems DPX 4 User Guide DotManager buttons access the Control Windows access the Setup Window access the RIP Management Windows start stop the RIPMate application or vay WorkMates Admin if PrintMate is installed Qee oe start the Hyperterminal communication application exit the DotManager application e save changes sm Windows DotManager has different windows for setting up and controlling the platesetter The windows fall into three basic categories Control Windows page 17 Setup Window page 21 RIP Management Windows page 22 Note In this section all the examples and screen views use metric measurement units The measurement unit can be changed to imperial units on the Setup tab ECRM imaging systems Chapter 5 Working with DotManager Control Windows These windows are used to set up and control the platesetter s basic operation To open a window first click on the access the Control Windows button and then click on the tab for the window you want to open e Platesetter Tab page 17 Media Tab page 19 Service Tab page 19 EcoPrefer
54. uaranteed To change a media setup 1 Select the correct media in the drop down list ECRM imaging systems Chapter 5 Working with DotManager 2 Change the appropriate settings 3 Click the Save button Service Tab The Service window displays some general info about the platesetter usage tools to manage the activator and stabilizer pumps DolManager Online FHEA Feo Fie yew Tons Heip e 08 P ialeqelley Meda EcoPtaleence Savant Gere al Tutal Operating Tir Total Acts Tin Total Ares P nerazel Total Plates Service Poeswerdt Tet Fisterelle Malut Meisaga Log 7 Opening LISE pire 1 g Opening USE poe 2 Corrada l denice Corman s completed Canisii completed The I O test window is started from the Service window General The General section displays some common statistics about the platesetter utilization All these parameters are lifetime information of the plate setter Total Operating Time Displays the total number of hours with power on Total Area processed Displays the total number of hours activated not counting standby time Total Black Area Processed Displays the total number of square meters processed 19 Chapter 5 Working with DotManager Total Plates Displays the total number of plates processed Refill Activator Refill the activator rack until it is completely full Stabilizer Refill the stabilizer
55. ught ups check box is unmarked RIPMate will disable all further output each time a caught up occurs Output will remain disabled until it is re enabled in RIPMate s Output Controller Monitor window If this check box is marked and the Retry on printer caught ups check box is also marked RIPMate will try to resend the page at half speed If it catches up again RIPMate will try at one quarter speed If it catches yet again RIPMate disables all further output If this check box is unmarked and the Retry on printer caught ups check box is unmarked RIPMate will move the job into the Held Queue Other jobs will print as usual If this check box is unmarked and the Retry on printer caught ups check box is marked RIPMate will retry at the two slower speeds but it output is still not possible the job will be moved into the Held Queue Other jobs will print as usual Retry on printer caught ups This check box controls weather or not RIPMate will try to output at a slower speed if a caught up occurs at the usual speed See the description for Stop on printer caught ups above for more information 22 Chapter 5 Working with DotManager 26 DPX 4 User Guide imaging systems DPX 4 User Guide Chapter 6 Calibration Why Is Calibration Necessary In order to compensate for dot gain and produce consistent output a platesetter must be calibrated for linearity A platesetter is linear when every tone spe

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