Luxel v6 2

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
LUXEL V-6 CTP FULLY-AUTOMATIC

UPGRADE INSTALLATION MANUAL
6800174004
P RELIMINARIES
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 the Technical Publications Man-
ager 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 publication. Any differences between the manual and equipment reflect improve-
ments introduced after publication of the manual. Changes, technical inaccuracies and
typographic errors will be corrected in subsequent editions. As part of our policy of con-
tinuous improvement, 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.
CAUTION: FFEI Limited cannot be held responsible for any loss or damage to customers
data by unauthorised third parties accessing the system. In the event that FFEI becomes
aware of any computer virus which will or is likely to affect the system it will take rea-
sonable 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 FUJIFILNM Corpora-
tion 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, Photoshop and Type Manager are trademarks of Adobe Systems Inc. that may
be registered in certain jurisdictions; Windows and Windows NT are trademarks of Micro-
soft Corporation that may be registered in certain jurisdictions; All other company names,
products or brand names are trademarks of their respective holders.
LUXEL V-6 CTP FULLY-AUTOMATIC U PGRADE
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 environment. This equipment generates, uses and can radiate radio fre-
quency 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 informa-
tion technology equipment. Class A equipment is intended for use in a light industrial or
commercial environment for which the 30 metre protection distance is used. Operation of
this equipment in a domestic or residential environment may result in interference to oth-
er equipment, in which case the user will be required to correct the interference at their
own expense. In some countries this equipment may be subject to restrictions on its use.
Where applicable the user should inform the relevant local authority that Class A Informa-
tion Technology Equipment has been taken into service.
This equipment may also be susceptible to strong electromagnetic fields and should not
be sited 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. Typical examples for the intended environment of this equipment would in-
clude:
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 pub-
lic 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.

P RELIMINARIES
About this Manual

This manual describes how to upgrade a Luxel V-6 platesetter systems from:
Manual to a Fully-Automatic Single-Cassette (SAL).
Semi-Automatic to a Fully-Automatic Single-Cassette (SAL).
Manual to a Multi-Cassette (MAL).
Semi-Automatic to a Multi-Cassette (MAL).
Fully-Automatic (SAL), with or without MLS, to a Multi-Cassette (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.
LUXEL V-6 CTP FULLY -A UTOMATIC U PGRADE
TABLE OF CONTENTS
Chapter 1 Introducing the Fully-Automatic Upgrades
1.1 Before Starting the Upgrade .............................................................. 1-1
1.1.1 Manual to Semi-Automatic .............................................................. 1-3
1.1.2 Semi-Automatic to Fully-Automatic (SAL) ..................................... 1-3
1.1.3 Manual to Fully-Automatic (SAL) .................................................... 1-3
1.1.4 Manual to Multi-Cassette (MAL) ..................................................... 1-3
1.1.5 Semi-Automatic to Multi-Cassette (MAL) ...................................... 1-4
1.1.6 Single-Cassette (SAL) to Multi-Cassette (MAL) ............................. 1-4
1.2 Unpacking the Upgrade Kit................................................................. 1-4
1.2.1 Consignment Check ........................................................................... 1-4
1.2.2 Inspection of Boxes ............................................................................ 1-4
1.2.3 Unpacking the Modules .................................................................... 1-6
1.2.4 Unpacking the Processor................................................................... 1-8
1.3 Handling the Equipment ...................................................................... 1-8
1.3.1 Using a Fork-Lift ................................................................................. 1-9
1.3.2 Completing the Installation Report ................................................ 1-9
Chapter 2 Safety on the Luxel V-6 CTP

2.1 Health and Safety at Work .................................................................. 2-1
2.1.1 Warnings and Cautions ..................................................................... 2-1
2.1.2 Clothing and Jewellery...................................................................... 2-2
2.1.3 Equipment and Tools ......................................................................... 2-2
2.1.4 Site Safety Rules.................................................................................. 2-2
2.2 Safety Labels and Indicators ................................................................ 2-2
2.2.1 Mains Rating Label............................................................................. 2-3
2.2.2 Drum and Traverse Warning Labels ............................................... 2-3
2.2.3 Autoloader Warning Labels ............................................................. 2-4
P RELIMINARIES
2.2.4 Autofeeder Warning Labels .............................................................2-5

2.2.5 Optics Warning Labels .......................................................................2-9
2.2.6 Electrical Warning Labels ..................................................................2-10
2.2.7 Interlock Warning Labels...................................................................2-11
2.2.8 Safety Devices ......................................................................................2-12
2.2.9 Unattended Equipment .....................................................................2-13
2.2.10 Dust Prevention .................................................................................2-13
2.2.11 Electrical Safety .................................................................................2-13
2.2.12 Mechanical Safety .............................................................................2-13
2.2.13 Spinner Safety....................................................................................2-14
2.2.13.1 Moving Parts Safety ......................................................................2-14
2.2.13.2 Acoustic Noise Safety....................................................................2-14
2.3 Safety Interlock System ..........................................................................2-15
2.3.1 Interlocked Covers ..............................................................................2-15
2.3.2 Locked Covers ......................................................................................2-16
2.3.3 Interlock Over-rides ............................................................................2-16
2.4 Laser Safety ................................................................................................2-17
2.4.1 Laser Precautions ................................................................................2-18
2.4.2 Laser Safety Shutter ............................................................................2-18
2.4.3 Laser Safety Warnings ........................................................................2-19
2.4.3.1 A DLA Room ....................................................................................2-20
2.4.3.2 A DLA Curtain .................................................................................2-20
Chapter 3 Installing the Single-Cassette Upgrade

3.1 Starting the Installation ........................................................................3-1
3.1.1 Heavy Lifting Operations...................................................................3-1
3.1.2 Pre-Install Checks ................................................................................3-2
3.2 Installing the Processor ..........................................................................3-2
3.2.1 Fit the Manual to Semi-Automatic UG ...........................................3-2
3.2.1.1 Set the Processor Height.................................................................3-2
3.2.1.2 Mate the Engine to the Processor..................................................3-3
3.3 Removing the Plate Lifter (Input Platen) ........................................ 3-4

3.4 Adjusting the Engine Input Conveyor Roller................................. 3-6
3.5 Fitting the Air Knife and Compressor .............................................. 3-7
3.6 Installing the Autoloader ..................................................................... 3-10
3.6.1 Remove Autoloader and Cassette Transit Fixings........................ 3-10
3.6.2 Integrating the Autoloader and Engine ........................................ 3-10
3.6.2.1 Autoloader with MLS ..................................................................... 3-12
3.6.3 Connect the Autoloader Cables ...................................................... 3-14
3.6.3.1 Connect the Processor Earth Cable ............................................... 3-14
3.6.3.2 G&J Earth Cable Fitting.................................................................. 3-14
3.6.3.3 Heights (Inca) Earth Cable Fitting ................................................. 3-16
3.6.4 Check the SAL MSB Links .................................................................. 3-17
3.6.5 Levelling the Trolley and Cassette .................................................. 3-17
3.7 Commissioning the Upgrade............................................................... 3-21
3.7.1 Enable the Machine Type ................................................................. 3-21
3.7.2 Upgrade Engine Firmware and PCI ................................................. 3-22
3.7.3 Update the Licences ........................................................................... 3-22
3.7.3.1 Installing Licences........................................................................... 3-23
3.7.4 Set up the Processor (if Installed) .................................................... 3-24
3.7.5 Check Cover Interlocks ...................................................................... 3-25
3.7.6 Run Test Plates .................................................................................... 3-26
Chapter 4 Installing the Multi-Cassette Upgrade

4.1 Start the V-6 MAL Upgrade ................................................................. 4-1
4.1.1 MAL Upgrade Kits .............................................................................. 4-1
4.2 Upgrade the Firmware and PC Software ........................................ 4-2
4.2.1 Upgrade the Engine Firmware ........................................................ 4-2
4.2.2 Upgrade the LuxelServer and PCI Dashboard............................... 4-3
4.2.3 System Pre-Requirements ................................................................. 4-3
4.2.4 Installing the LuxelServer ................................................................. 4-4
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4.2.4.1 Install the LuxelServer (Device Drivers)..........................................4-4

4.2.4.2 Install the LuxelDesktop .................................................................4-4
4.2.5 Installing New Licence Keys ..............................................................4-4
4.2.5.1 Obtaining Licence Keys...................................................................4-4
4.3 Upgrade an Existing SAL Autoloader ...............................................4-6
4.4 Install the Upgrade MAL Autoloader ...............................................4-8
4.4.1 Remove Autoloader and Cassette Transit Fixings ........................4-9
4.4.2 Integrating the Autoloader and Engine ........................................4-9
4.4.3 Connect the Autoloader Cables .......................................................4-10
4.4.3.1 Connect the Processor Earth Cable ................................................4-11
4.4.3.2 G&J Earth Cable Fitting ..................................................................4-11
4.4.3.3 Heights (Inca) Earth Cable Fitting ..................................................4-12
4.5 Install the MAL Autofeeder .................................................................4-13
4.5.1 Integrate and Level the Autofeeder (Basic Fit) .............................4-13
4.5.2 Connect the Autofeeder Cables .......................................................4-16
4.5.3 Remove Transit Fixings Using the Brake Override .......................4-21
4.5.3.1 Set up the Brake Override ..............................................................4-21
4.5.3.2 Remove the Transits........................................................................4-21
4.5.3.3 Remove the Brake Override ...........................................................4-23
4.5.3.4 Lower the Elevator..........................................................................4-23
4.5.3.5 Raise the Elevator ...........................................................................4-23
4.5.4 Remove the Transit Fixings ...............................................................4-23
4.5.5 Integrate and Level the Autofeeder (Fine Level) .........................4-26
4.5.5.1 MSB PCB Links .................................................................................4-29
4.5.6 Levelling the Trolley ...........................................................................4-29
4.6 Commissioning the Upgrade ...............................................................4-31
4.6.1 Enable the Machine Type ..................................................................4-31
4.6.2 Update the Licences ...........................................................................4-31
4.6.2.1 Installing Licences ...........................................................................4-32
4.6.3 Set up the Processor (if Installed) ....................................................4-33
4.6.4 Check Cover Interlocks (Autoloader) ..............................................4-34
4.6.5 Run Test Plates .....................................................................................4-35
Chapter 5 Commissioning the Luxel V-6 Upgrade

5.1 Starting to Commission the Platesetter........................................... 5-1
5.2 Initial Software Checks and Setups ................................................... 5-2
5.2.1 Open Main Diagnostics and Check Engine Clock ........................ 5-2
5.2.2 Check Power Supply Voltages.......................................................... 5-3
5.2.3 Check Cover Interlocks ...................................................................... 5-3
5.2.4 Check Plate Feeds ............................................................................... 5-5
5.2.5 Set up the Processor (if Installed) .................................................... 5-5
5.3 Setting up Optics and Imaging........................................................... 5-6
5.3.1 Check Beam Focus .............................................................................. 5-6
5.4 Checking Plate Output (Without a Punch) ..................................... 5-10
5.4.1 Check Image Skew Accuracy ............................................................ 5-10
5.4.2 Check Image Start and Edge Accuracy ........................................... 5-11
5.4.3 Set Image Base Offset........................................................................ 5-12
5.4.4 Set Image Edge Sensor Offset.......................................................... 5-13
P RELIMINARIES
INTRODUCING THE FULLY-
AUTOMATIC UPGRADES
This chapter outlines the main equipment changes and installation
steps for the manual system upgrade.
1.1 Before Starting the Upgrade................................................................ 1-1
1.2 Unpacking the Upgrade Kit ................................................................. 1-4
1.3 Handling the Equipment ...................................................................... 1-8
1.1 Before Starting the Upgrade

NOTE: Before starting the upgrade, the site should be assessed
by the Distributor for all site requirements described in the Luxel
V-6 Series CTP Pre-Installation Guide.
This installation manual explains how to upgrade a currently

installed manual Luxel V-6 B2 platesetter from a manual or semi-
automatic (see Figure 1.1 on page 1-2) to a:
SAL: fully-automatic single-cassette autoloader (see
Figure 1.2 on page 1-2), or
MAL: fully-automatic multi-cassette autoloader (see
Figure 1.3 on page 1-3).
1-2 INTRODUCING THE FULLY -A UTOMATIC U PGRADES
PROCESSOR
ENGINE
PLATEN HEIGHT
DEPTH
WIDTH
Figure 1.1 Luxel V-6 semi-automatic
PROCESSOR
ENGINE
AUTOLOADER
CASSETTE
& TROLLEY
HEIGHT
DEPTH
WIDTH
Figure 1.2 Luxel V-6 single-cassette (SAL)

LUXEL V-6 CTP FULLY-A UTOMATIC UPGRADE 1-3
AUTOFEEDER
Figure 1.3 Luxel V-6 multi-cassette (MAL)
1.1.1 Manual to Semi-Automatic

See Section 3.1 on page 3-1 for details on starting this upgrade
kit.
1.1.2 Semi-Automatic to Fully-Automatic

(SAL)
kit.
1.1.3 Manual to Fully-Automatic (SAL)

kit.
1.1.4 Manual to Multi-Cassette (MAL)

See Section 4.1.1 on page 4-1 for details on starting this upgrade
kit.
1.1.5 Semi-Automatic to Multi-Cassette

(MAL)
kit.
1.1.6 Single-Cassette (SAL) to Multi-Cassette

(MAL)
kit.
1.2 Unpacking the Upgrade Kit

1.2.1 Consignment Check
The local engineer or agent must check, 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
consignment comprises a set of boxes containing the following
items:
processor (manual upgrades only)
Autoloader
Trolley and Cassette
Stacker (if ordered)
Installation Pack (all variants) - see Table 1.1 on page 1-8.
Dimensions and weights of the packed modules for all variants is
given in the Luxel V-6 Series CTP Platesetter Pre-Installation
Guide.
1.2.2 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 1.4 on page 1-5 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.
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 1.4 Mishandling indicators
NOTE: If the Tip or Drop indicators on the engine are tripped

then the engine has been affected.
Units may be removed from their box only by an approved

engineer or representative. If there has been damage during
shipping, unpacking will have to be delayed. Do not proceed with
unpacking until authorized by the shipping and insurance agents.
NOTE: Markings on the box indicate which side is the front of

the module.
1.2.3 Unpacking the Modules

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.
CAUTION: Two people are required to manoeuvre the autoloader

while it is supported by castors. The module is very heavy and
includes delicate items of equipment.
CAUTION: Five people are required to lift the processor. Four to

lift the Processor and one to remove the palette.
CAUTION: Modules should only be unpacked after a 24 hours

acclimatisation period in the operating temperature and
humidity environment.
Unpack each box using the instructions attached to the outside of

the box. A typical unpacking method for an engine, or stacker is
as follows:
1. Locate the box in a position where there is enough room to
unpack and fork-lift the module from its box.
2. Cut any bands securing the box.
3. Lift off the cardboard top cap (two-man lift).
4. Remove any top protective foam inserts and lift off the box sleeve
to reveal the module on a wooden palette base.
5. Check that the foil vacuum seal surrounding the module is
shrunk, indicating that the vacuum is still present. If the seal is
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 1.5 on page 1-7, before lifting the unit.
8. Remove any foam inserts around the palette.
FOAM FORK STOP BEARING FORK STOP FOAM

INSERT BLOCK BLOCKS BLOCK INSERT
PLAN VIEW
FRONT
FORK REMOVEABLE FORK

FRONT BLOCK
Figure 1.5 Unpacking the module boxes
9. Use the fork-lift truck to remove the module from the palette, see
also Section 1.3.1 on page 1-9. 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).
NOTE: There should be an acclimatisation period of 24 hours

between breaking the seal and starting the machine.
11. Locate the Accessories pack and check that the items in Table 1.1
on page 1-8 are shipped.
Table 1.1 Upgrade Accessories pack (V-6 to SAL)

1 Input roller guide plate with M4 screws and washers
2 Engine firmware/PCI and RIP
3 Upgrade Installation Manual
4 Processor comms cable (manual to semi only)
5 Processor buffer and screws (manual to semi only)
6 Output stretcher (manual to semi only)
12. Arrange locally for the removal of disposable packaging

materials. The box cardboard and foam are all recyclable
materials.
1.2.4 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 obtain information on

how to unpack the processor.
1.3 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

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.
1.3.1 Using a Fork-Lift

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

centrally 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.
1.3.2 Completing the Installation Report

IMPORTANT: After the platesetter has been commissioned and
accepted by the customer, it is important to complete the Installa-
tion Report to ensure the site configuration is fully supported by
FFEI (UK).
1-10 INTRODUCING THE FULLY -AUTOMATIC U PGRADES
SAFETY ON THE LUXEL V-6 CTP
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 installation.
2.1 Health and Safety at Work ................................................................... 2-1
2.2 Safety Labels and Indicators............................................................... 2-2
2.3 Safety Interlock System ..................................................................... 2-15
2.4 Laser Safety ........................................................................................ 2-18
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.
Particular attention should be given to those sections covering
personal 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.
2.1.1 Warnings and Cautions

There are two safety categories given in this manual:
2-2 S AFETY ON THE LUXEL V-6 CTP
WARNINGS are given for conditions which may endanger life.
WARNING: The instructions given in warnings must be followed

precisely. 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 equip-
ment manuals associated to the equipment.
Never attempt to perform procedures that are not included in
this manual.
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 2.1 on page 2-3 to Figure 2.10 on page 2-12.
2.2.1 Mains Rating Label

See Figure 2.1 on page 2-3.
ERT
INT EK
ETL LISTED
CONFORMS TO
UL STD 60950
C US
LIS T E D CERTIFIED TO
92206 CAN/USA STD C22.2 NO. 60950
Product: LUXEL
Model No: V-6 CTP
Serial No:
Volts: 230 50 / 60Hz ~
Max Current: 10 A
Manufactured:
This device complies with Part 15 of the FCC rules

and is subject to the following two conditions:
1. This device may not cause any harmful
interference
and
10 Aany interference
2. This device must accept
received including interference that may
cause undesired operation.
IMAGING ENGINE This Class A digital apparatus meets all the
(REAR) requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numerique de la classe A respecte
toutes les exigences du Reglement sur le materiel
brouilleur du Canada.
This laser conforms to the applicable requirements of
21 CFR Sub chapter J.
FFEI Ltd.
PETERBOROUGH
ENGINE (REAR VIEW) ENGLAND CLASS 1 LASER
LASER KLASSE 1
LASER DE CLASSE 1
7550 854D 04
Figure 2.1 Mains input and rating label
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 Amendment 2 / 2001
Figure 2.2 Drum interior: moving parts and edge detect warning
labels
2.2.3 Autoloader Warning Labels

Figure 2.3 on page 2-5 shows a moving parts label on the PTM
feed head
Figure 2.3 Plate feed moving parts
2.2.4 Autofeeder Warning Labels

Figure 2.4 on page 2-6 to Figure 2.7 on page 2-9 show the warn-
ing labels on the Autofeeder.
WARNING
ENSURE MAINS SUPPLY DISCONNECTED
BEFORE SERVICING
Figure 2.4 Autofeeder: elevator motor warning labels

Figure 2.5 Autofeeder: elevator warning label

USER SIDE
SERVICE SIDE
Figure 2.6 Autofeeder elevator moving parts warning labels

AUTOLOADER
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 CTP
LASER RADIATION - AVOID EYE

OR SKIN EXPOSURE TO DIRECT
OR SCATTERED RADIATION
WAVELENGTH & MAX OUTPUT

405 nm/45 W
CLASSIIIB LASER PRODUCT
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 CTP F ULLY-A UTOMATIC U PGRADE 2-11
Attention!
high tension
Vorsicht!
Hochspannung
Pre caution!
haute tension
Precaucion!

alta tension
T2A H 250V
Figure 2.9 Interlock box: high-tension warning label
2.2.7 Interlock Warning Labels

Figure 2.10 on page 2-12 (manual and semi-automatic) shows the
areas of laser beam risk to the engineer when the interlocked
covers are opened and the interlocks are defeated.
Figure 2.10 Typical Interlock Defeated Warning labels
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.
LUXEL V-6 CTP F ULLY-AUTOMATIC U PGRADE 2-13
Safety interlocks.
WARNING: Unless essential for commissioning, and under pre-

scribed 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 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.
2.2.12 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
D) punch.
2.2.13 Spinner Safety

2.2.13.1 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 serious injury if accidentally touched. Make sure the spin-
ner has stopped rotating before accessing a drum with the inter-
locks defeated.
2.2.13.2 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 Engineers Reference Guide.
2.3.1 Interlocked Covers

The following cover, shown in Figure 2.11, is interlocked:
1. Engine, user side cover.
Figure 2.11 Location of interlock covers: semi-automatic
WARNING: If the platesetter has to be run with a cover open and

the interlocks over-ridden, extreme care must be taken to avoid
the following hazards: rotating spinner, laser beam, moving
plate motors.
WARNING: All unqualified personnel must be prohibited from

the area, while the machine is in the over-ridden state.
WARNING: The Laser Safety Officer must be informed when the

machine is in this state.
2.3.2 Locked Covers

CAUTION: After completing the upgrade, 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 Users Safety Guide.
2.3.3 Interlock Over-rides

Interlocks are defeated by inserting the approved engine
actuator key into the interlock switch shown in Figure 2.12 on
page 2-17 (engine) and Figure 2.13 on page 2-17 (autoloader).
Operating an over-ridden system allows the platesetter to
generate a laser beam, rotate the spinner and move the plate
drive motors.
ENGINE FRAME
DOOR
SWITCH
OVERRIDE
KEY
Figure 2.12 Fitting the interlock over-ride key: engine
AUTOLOADER SERVICE SIDE
TO OVERRIDE:
INSERT KEY AND
TWIST CLOCKWISE
TO REMOVE KEY:
TWIST ANTI-CLOCKWISE
AND REMOVE
INTERLOCK
OVERRIDE
KEY
INTERLOCK
SWITCH
Figure 2.13 Fitting the interlock over-ride key: autoloader

While the key is in the switch, it is impossible to shut the
interlocked 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 V-6 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.
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 2.14 on page 2-19, 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
command:
diagnostics/service/optics/laser/ldisable
OPTICS BASE
(USER END)
SHUTTER
OPEN
CLOSED
Figure 2.14 Optics 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
engineer 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 serious damage and possible blindness.
When working on a Class IIIB laser source, always wear goggles
capable 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
potentially hazardous. Exercise extreme caution while servicing
the platesetter 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
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
interlocks over-ridden using the approved method. Under these
circumstances, only the installation engineer should be in the
Designated Laser Area (DLA). The DLA may be a room, a
curtained 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 2.15 on page 2-21.
A red warning light, positioned above the door(s) leading to
the room, illuminated whenever there is a laser radiation haz-
ard.
LASER CLASS 3B OPERATIONS

WHEN WARNING LIGHT IS ON
LASER CLASS IIIb OPERATIONS NO ENTRY TO UNAUTHORISED
PERSONNEL
WHEN WARNING LIGHT IS ON
EUROPEAN
NO ENTRY TO UNAUTHORISED
PERSONNEL
U.S.A.
Figure 2.15 Typical laser warning signs
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 2.15 on page 2-21 are recom-
mended.
INSTALLING THE SINGLE-CASSETTE
UPGRADE
This chapter shows how to install and connect the main platesetter
modules for SAL upgrade.
3.1 Starting the Installation........................................................................ 3-1
3.2 Installing the Processor....................................................................... 3-4
3.3 Removing the Plate Lifter (Input Platen) ............................................ 3-2
3.4 Adjusting the Engine Input Conveyor Roller ..................................... 3-6
3.5 Fitting the Air Knife and Compressor............................................... 3-10
3.6 Installing the Autoloader ................................................................... 3-21
3.7 Commissioning the Upgrade............................................................. 3-21
3.1 Starting the Installation

3.1.1 Heavy Lifting Operations
Two or more people are normally required for any heavy lifting
procedures where you need to:
manoeuvre the autoloader into position
install the processor (this unit requires four people to lift
the unit and one to remove the palette)
3-2 INSTALLING THE SINGLE-C ASSETTE U PGRADE
CAUTION: Obtain assistance before lifting or manoeuvring any

large modules.
3.1.2 Pre-Install Checks

Before installing the upgrade make sure the pre-install checks in
the Pre-Installation Guide have been completed, especially if the
platesetter is being moved to a new working position.
NOTE: Before installing the Fully-Automatic UG kit, fit the

Manual to Semi-Automatic UG kit using information in Section
3.2.1 on page 3-2.
3.2 Installing the Processor

CAUTION: Lifting the processor unit is a five-man operation.
3.2.1 Fit the Manual to Semi-Automatic UG

1. Fit the output stretcher to the rear of the engine.
2. Fit the buffer to the processor.
3.2.1.1 Set the Processor Height
Using the supplied OEM Installation Manual, install the processor
and its chiller unit.
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.
3.2.1.2 Mate the Engine to the Processor

1. Fit the processor input plate (buffer) with the screws supplied in
the Accessory Pack.
2. Position the engine frame against the processor buffer frame.
3. Adjust the engine feet until both frames are roughly at the same
height.
4. Level the engine drum/beam assembly in both planes using a
spirit level.
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.
7. Check the drum assembly is still level in both planes and re-adjust
if necessary.
8. Refit the processor covers.
9. Connect the comms cable from the processor to the engine.
10. Connect the processor power cables.
PLASTIC INPUT
ROLLERS RULER
ENGINE PROCESSOR
OUTPUT
HEATER
GUIDE
PLATE
2 mm
RUBBER NIP
ROLLERS
1012 mm
Figure 3.1 Levelling the engine and processor
3.3 Removing the Plate Lifter (Input Platen)

1. Remove the top engine cover to gain improved access. The cover
is secured by 2-off posi-screws accessed from inside the user door.
2. Lift off the two engine doors. The service door is secured by 2-off
posi-screws underneath.
3. Remove the input roller cover above the lifter by:
A) removing the 2-off pozi-screws from each door side
B) detach the cover by lifting it up to unhook it from the
engine.
4. Disconnect the following cables (inline connectors) between the
lifter and the engine:
A) V_B2_Frontsensors (0508)
B) V_B2_M11 (0509)
C) EM2 plate center motor
5. Remove the 3-off pozi-screws holding the lifter to the engine
from each door side.
6. Using two people, lift the unit away from the engine.
NOTE: The plate lifter does not need to be returned to FFEI (UK).
INPUT ROLLER
COVER
POSIDRIVE SCREW
SLOT FIXING
POSIDRIVE SCREW
(3-OFF ON EITHER SIDE)
PLATE LIFTER
Figure 3.2 Removing the plate lifter

3.4 Adjusting the Engine Input Conveyor Roller

See Figure 3.3 on page 3-6 and Figure 3.4 on page 3-7.
1. Move the first input roller and its associated drive gear on the
input conveyor to the autoload position shown in Figure 3.3 on
page 3-6 as follows:
INPUT GUIDE
PLATE
INPUT
CONVEYOR
AUTOLOADER
INPUT CONVEYOR ROLLER POSITION
ROLLER BEARING
Figure 3.3 Moving the input roller

A) Remove the input roller drive gear fixing screw and gear
assembly, and retain, see Figure 3.4 on page 3-7.
DRIVE GEAR
Figure 3.4 Moving the input roller drive gear
B) Remove the roller bearing circlip on the user side and push
the roller to the service side to release the roller.
C) Move the roller to the autoloader roller position shown in
Figure 3.3 on page 3-6.
D) Refit the drive gear on the input conveyor so that it
relocates in the mounting immediately above its original
position.
2. Attach the input guide plate, shown in Figure 3.3 on page 3-6, to
the input conveyor using the 4-off M4 panhead screws and
washers supplied.
3.5 Fitting the Air Knife and Compressor

1. Attach the air knife assembly to the input conveyor brackets (2-
off posi-screws).
2. Attach the knife elbow on the MMI side.
AIR KNIFE
KNIFE ELBOW
Figure 3.5 Fitting the air knife
3. Fit the connecting tube to the elbow and route towards the
compressor box at the output end.
4. Fit the compressor housing assembly into the three slot holes on
the frame at the MMI end (output) and secure. A 4th screw
secures the other side of the housing to the output support
bracket inside the top cover. See Section 3.6 on page 3-9.
SCREW
FIXING
SCREW
FIXINGS
Figure 3.6 Fitting the compressor

3-10 INSTALLING THE SINGLE -C ASSETTE U PGRADE
5. Remove the engine lower rear panel.
6. Connect the mains cable, V6_Comp (099700542), between the
compressor and the IEC output on the Interlock box. Secure the
cable to the frame along its route.
7. Replace the rear panel.
3.6 Installing the Autoloader

3.6.1 Remove Autoloader and Cassette
Transit Fixings
1. Remove the top interlocked cover from the autoloader.
2. Remove the nudger lift and diverter transit fixings (2-off M4), if
fitted.
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 polystyrene block holding the autoloader cassette
input door in position.
3.6.2 Integrating the Autoloader and Engine

NOTE: This procedure applies to an autoloader without a manual
loading slot (MLS). If the autoloader has an MLS then complete
the procedure in Section 3.6.2.1 on page 3-12.
The autoloader and engine are integrated as follows:

1. Remove the lower front cover on the autoloader (2-off M4).
2. Detach the adaptor assembly from the shipped autoloader frame
(5-off M5 screws). See Figure 3.8 on page 3-12.
Leave the free end of the interlock cable in place on the
autoloader.
3. Fit the adaptor assembly to the input of the engine. Locate the
assembly and attach with 4-off M4 pozi-screws on each side from
the user and service door entries.
4. Mate the autoloader to the engine adaptor assembly as follows,
see Figure 3.8 on page 3-12:
A) Locate the two adaptor pins inside the two autoloader
keyholes.
B) Obtain the 4-off seating plates (anchor feet) from the
accessories pack and locate them underneath each
autoloader jacking bolt, see Figure 3.7 on page 3-11.
C) Raise the autoloader feet gradually (using an 8 mm
spanner) so that the two adaptor pins are touching the
bottom lip of the keyhole slot, see Figure 3.8 on page 3-12.
LOCKING
NUT
8 mm
JACKING
BOLT
SEATING
PLATE
Figure 3.7 Adjusting the autoloader feet
5. Use a spirit level on the top frame cover to check that the
autoloader is level. Check that the adaptor assembly is level and
adjust, if necessary.
6. Lock the four autoloader feet.
7. Using the previously removed 5-0ff M5 screws, fix the autoloader
to the adaptor assembly, see Figure 3.8 on page 3-12.
AUTOLOADER
ADAPTOR
ASSEMBLY
KEYHOLE
(2-OFF) AUTOLOADER
M5 SCREW
(5-OFF)
KEYHOLE
ADAPTOR
ASSEMBLY
ADAPTOR
PIN
(2-OFF)
PIN IN SLOT
CONTACTING
LOWER LIP
Figure 3.8 Locating the adaptor pins and keyhole slots
3.6.2.1 Autoloader with MLS

Remove the following (see Figure 3.9 on page 3-13):
A) Tape holding the door closed.
B) Transit screw on the M-roller assembly.
TRANSIT
SCREW
M-ROLLER
ASSEMBLY
MLS COVER
TAPE
(BOTH ENDS)
NUDGER
ARM
NUDGER
TRANSIT
FIXING
NUDGER
FRAME
Figure 3.9 MLS transit screw

3.6.3 Connect the Autoloader Cables

1. 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 autoloader top cover is removed. If this cable is not fitted and
the shorting connector is removed, then the machine is in a dangerous
state for the operator.
2. V6A_CAN_AUTO: from MSB3 SK1 to MSB2 SK3. This cable is in

the Accessories pack. See Section 3.10 on page 3-14.
MSB2
MSB1
Figure 3.10 Location of MSB2
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.
3.6.3.1 Connect the Processor Earth Cable

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

From the engine end:
1. Switch off the engine and isolate from mains supply.
2. Obtain the V6_Processor_Earth (99700651) from the support pack
and pass one end through the cable entry slot, see Figure 3.11 on
page 3-16 (a).
3. Fit one end of the cable to the base earth stud.
From the processor end:
5. Remove the processor side cover to gain access to the mains
electrical box.
6. Feed the cable end, marked G&J through the cable entry hole at
the back of the box.
7. Fit the cable to the earth stud shown in Figure 3.11 on page 3-16
(b).
8. Replace the processor cover.
CABLE
ENTRY
BASE
EARTH
STUD
CABLE
ENTRY
a) V-6 ENGINE SLOT
EARTH
STUD
b) G & J PROCESSOR
BASE
EARTH
STUD
c) HEIGHTS INCA PROCESSOR
Figure 3.11 Fitting the processor earth to the engine
3.6.3.3 Heights (Inca) Earth Cable Fitting

and pass one end through the cable entry slot (see Figure 3.11 on
page 3-16 (a).
4. Route the cable to the processor earth stud shown in Figure 3.11
on page 3-16 (c).
3.6.4 Check the SAL MSB Links

Make sure all three plate handling MSB links match the settings in
Table 3.1 on page 3-17.
Table 3.1 MSB 1-3 fully-automatic (SAL) link settings

MSB: LINK 1 LINK 2
1 NOT FITTED NOT FITTED
2 NOT FITTED NOT FITTED
3 FITTED FITTED
3.6.5 Levelling the Trolley and Cassette

1. Prepare the autoloader and cassette as follows:
A) Remove the cassette lid.
B) Remove the two side bumpers from the cassette platen (3-
off M4 screws).
C) Tape the cassette input door to the top cover so that it is
held open.
D) Temporally remove the service side autoloader door and
open the paper bin door.
E) Remove the protect cover on the users side (2-off, M4
screws) so that there is a clear side view of both cassette
locating pins on the autoloader. See Figure 3.12 on page 3-
18.
PROTECT
COVER
ADAPTOR
ASSEMBLY
Figure 3.12 Removing the protect cover
2. Very carefully, push the trolley into the autoloader bay and check
from each side if the two cassette locating pins line up with their
two holes on the cassette interface, see Figure 3.13 on page 3-19.
LOCATING
PIN LATCH
BUMPER
Figure 3.13 Autoloader locating pins
3. Adjust the trolley height as follows (see Figure 3.14 on page 3-

20):
A) Using an adjustable spanner (up to 30 mm jaw span),
loosen the four locknuts.
B) Adjust the castor wheel height by turning the wheel hood
(clockwise to raise).
C) Put a 600 mm spirit level lengthways on the platen and
keep adjusting the height and level of all four wheels until
the locating pins are lined up with the cassette holes.
D) If the adjustment length on the bolt is not enough (trolley
needs to go higher), then remove the castor and refit with
the locknuts below the pads.
TROLLEY
CASTOR WHEEL
(4-OFF)
LOCKNUT
PAD
TROLLEY
BASE
LOCKNUT
(BELOW PAD POSITION)
WHEEL
WHEEL HOOD
(CLOCKWISE TO RAISE)
Figure 3.14 Adjusting the trolley height

4. Pull out the cassette and tighten all four castor locknuts.
5. Push the cassette back into the bay and make sure that the
locating pins locate smoothly into the cassette, and you can hear
the cassette latch snap to engage correctly.
6. If the cassette fails to latch then readjust the trolley height.
7. Refit the autoloader doors and covers.
8. Refit the protect cover on the service side.
9. Refit the cassette lid, bumpers and release the input door flap.
3.7 Commissioning the Upgrade

3.7.1 Enable the Machine Type
This procedure sets the machine type.
1. Refit all the doors and covers.
2. Connect a PC terminal to the engine RS232 Diagnostics output or
open HyperTerminal on the RIP PC.
3. Power up the engine and press [ctrl-c] after the first message to
stop the boot. Note that this message appears very quickly after
pressing the Power On switch. The display indicates the system
remains in Boot mode.
If the Formatter Board is running PHASE 10 (or higher), enter:
main> machine 13
then continue from step 7.
4. If the Formatter Board is running PHASE 8 or 9 then enter:
main>machine
5. Use the left arrow [<-] to select Vsix B2 Auto:
6. Enter [Return] to obtain the main> prompt.

7. Reboot the engine and stop at the first [Ctrl-c] request to remain
in Boot mode.
3.7.2 Upgrade Engine Firmware and PCI

NOTE: Refer to the Firmware Release Notes on the CD before
starting to download firmware.
1. With the system in Boot mode, check that all the firmware
revisions are compatible for:
FBoard (FB) Boot and Application
LCB Boot and Application
MSB1 Boot and Application

STB Boot and Application.

2. If there is any firmware incompatibility then the firmware should
be downloaded from the CD supplied with the upgrade kit. Once
this has been done upgrade the LuxelServer and PCI from the CD.
3. Details of RIP compatibility is listed in the Firmware Release
Notes.
4. Reboot the platesetter.
3.7.3 Update the Licences

New licences, created as part of the autoloader upgrade order,
are installed using the procedure in the Luxel V-6 CTP Installation
Manual.
Once the product is ready for shipping, you can obtain its licence
key(s) from SIO in advance of the installation start date. Other
sections on the Report can be completed and submitted at the
end of the installation.
All new hardware upgrades to an existing machine are supplied
with their own Installation Notes as part of the kit.
The procedure for obtaining licence keys for all newly ordered
options on an installed machine is the same as a full installation,
except that the Distributor will also receive a Faxed Order
Confirmation with the new key.
For a fully-automatic system there must be valid licences for
options:
Manual to Semi.
Semi to Auto.
1. Check the current set of options by selecting Engine Info from the
RUN or PAUSE keypad.
Select Review Licence Options to check installed licences.
3.7.3.1 Installing Licences

To obtain the licence key for the ordered option(s), navigate to
the FFEI SIO site (http://touchbase.ffei.co.uk) and open the online
Installation Report from Installation Data for the customer.
2. Open the Report to display a list of licence keys for the
configuration.
NOTE: One key may include all the ordered options for an
upgrade.
3. Copy and paste a key into the Licence Manager (Maintenance) on

the PCI, and press Confirm. See Figure 3.15 on page 3-24.
ENTER KEY
CONFIRM
Figure 3.15 Licence Manager: entering the key
4. Make sure the customer is aware of their new keys by supplying a

text file copy.
5. After installing new licence(s), reboot the engine.
3.7.4 Set up the Processor (if Installed)

An RS232 communications link setting between the Engine and
the Processor allows the two units to share the same protocol for
passing diagnostics and media handling commands.
1. Set up the NVRAM parameter:
>snv HAS_PROCESSOR 1
2. Restart the LuxelServer and reboot the platesetter.
3. Ensure that the processor comms preference is enabled from the
PCI menu.
4. Check that the processor and engine are able to communicate by
entering:
diagnostics/service/medproc/status
5. Set the Processor plate thickness:
medproc/thickness [value]
where the [value] is the plate thickness (in m) as:
0.15 = 150
0.20 = 200
0.24 = 240
0.30 = 300.
6. Check in the processor display that the processor pre-heat
temperature zones change as plates of different thickness are
changed:
0.15 = P1 (G&J)
0.20 = P2 (G&J)
0.24 = P3 (G&J)
0.30 = P4 (G&J).
7. Check the distance and speed parameters for the processor while
the test plates are running.
3.7.5 Check Cover Interlocks

See also Section 2.3 on page 2-15.
1. While the system is switched on, check the operation of the
engine and autoloader interlocks. With the user door and
autoloader cover closed, enter:
service/sensors/environ
Check that the interlock status message is OK, all covers closed,
both contactors closed.
2. Remove the autoloader top cover.
Check the status changes to code $1e INTERLOCK BROKEN:
Autoloader cover open when the environ command is run.
Check if the following devices stop:
plate handling motors
laser light
spinner
vacuum pump.
3. Replace the autoloader cover and reboot.
4. Open the user door and check if the following devices stop:
spinner stops
laser light
vacuum pump.
5. While the interlocks are enabled, check that the correct Error
Handling screen and error code appears when a cover is opened,
and the machine fully reboots when the cover is replaced:
572: engine user door opened
579: autoloader top cover removed.
3.7.6 Run Test Plates

See the Luxel V-6 Series Engineers Reference Guide.
1. Load the cassette with a plate type and size that have previously
been used with the old manual engine.
2. Output a single plate from Media Tools to check that the
autoloader, engine and processor media handling are correct.
3. Output a stock image and to check the engine and processor
outputs.
Check for image skew and image start positions.
4. Output customer job images to check the RIP.
INSTALLING THE MULTI-CASSETTE
UPGRADE
This chapter shows how to upgrade a single-cassette system to a MAL
system.
4.1 Start the V-6 MAL Upgrade .................................................................. 4-1
4.3 Upgrade an Existing SAL Autoloader................................................. 4-6
4.4 Install the Upgrade MAL Autoloader .................................................. 4-8
4.5 Install the MAL Autofeeder ................................................................ 4-13
4.6 Commissioning the Upgrade............................................................. 4-31
4.1 Start the V-6 MAL Upgrade

4.1.1 MAL Upgrade Kits
A supplied MAL upgrade can be one of three available kits with
required actions:
1. V-6 Manual to Multi-Cassette (MAL):
A) Follow the procedures in Section 3.2 on page 3-2 to Section
3.5 on page 3-7 to upgrade the engine first.
B) Continue to Section 4.4 on page 4-8 to install the MAL
autoloader.
4-2 INSTALLING THE MULTI-C ASSETTE U PGRADE
C) Continue to Section 4.5 on page 4-13 to install the MAL
autofeeder.
2. V-6 Semi-Automatic to a Multi-Cassette (MAL):
A) Follow the procedures in Section 3.2 on page 3-2 to Section
3.5 on page 3-7 to upgrade the engine first.
autoloader.
C) Continue to Section 4.5 on page 4-13 to install the MAL
autofeeder.
3. V-6 Single-Cassette (SAL) with or without MLS to Multi-Cas-
sette (MAL):
A) Follow the procedure in Section 4.3 on page 4-6 below to
upgrade an existing SAL autoloader.
autofeeder.
4.2 Upgrade the Firmware and PC Software

4.2.1 Upgrade the Engine Firmware
NOTE: Refer to the Firmware Release Notes on the CD before
starting to download firmware.
1. With the system in Boot mode, check that all the firmware
revisions are compatible for:
FBoard (FB) Boot and Application
LCB Boot and Application

STB Boot and Application.

2. If there is any firmware incompatibility then the firmware should
be downloaded from the CD supplied with the upgrade kit.
3. Details of RIP compatibility is listed in the Firmware Release
Notes.
4. Reboot the platesetter.
4.2.2 Upgrade the LuxelServer and PCI Dash-

board
NOTE: The LuxelServer Installation Guide and Release Notes,
shipped on the LuxelServer software media, provide the latest
information on how to install the software. Always refer to this
information before starting the installation.
Two software bundles as two CDs are installed at this stage:

LuxelServer: includes the device driver. This is always
installed before the PCI Dashboard and any new
installations of the RIP.
Luxel Desktop: includes the V6 dashboard.
4.2.3 System Pre-Requirements

1. The PC operating system must be one of the following for
running the LuxelServer and Dashboard:
Windows 2000 NT Server (with Service Pack 4), or
Windows 2003 Server, or
Windows XP Pro (with Service Pack 1).

2. In addition, the PC must have installed:
Acrobat Reader (minimum level V6.0)
Microsoft (Hilgraeve) Hyperterminal (minimum level V6.3).
4.2.4 Installing the LuxelServer

NOTE: Remove any previous installations of the LuxelServer
before the upgrade installation.
LuxelServer must be running before the engine and PCI Dash-
board functions correctly.
The software on the supplied Luxel V6 CTP Disk 1 CD is loaded
using an InstallShield Wizard.
Note the following:
1. Install the PCI software before the RIP software.
2. If a version of the software is still loaded (and is not at the cor-
rect level), remove it using the procedure in the PCI Installa-
tion Guide.
3. After loading PCI software:
A) restart the PC
B) switch on the platesetter
4.2.4.1 Install the LuxelServer (Device Drivers)

Device drivers are installed automatically from the LuxelServer
CD. If there any problems then consult the LuxelServer Installa-
tion Notes.
4.2.4.2 Install the LuxelDesktop

The Dashboard software is installed automatically once the CD is
inserted.
4.2.5 Installing New Licence Keys

4.2.5.1 Obtaining Licence Keys
IMPORTANT: Completing and submitting an Installation Report
ensures that FFEI (UK) will have the correct information to offer
long-term support for the customer.
Installation Report from Installation Data.
1. Select Edit and enter:
A) Name of the customer.
B) Start date of the installation.
2. Save the Report.
3. Open the Report again to display a list of licence keys for the
configuration.
NOTE: One key may include all the ordered options for an instal-
lation.

the PCI, and press Confirm.
5. Switch on the engine.
6. Make sure the customer is aware of their keys by supplying a text
file copy.
ENTER KEY
CONFIRM
New software options will normally require the local service engi-
neer to install the licence and check the machine output. The pro-
cedure for obtaining licence keys for all newly ordered options on
an installed machine is the same as above, except that the Distrib-
utor will also receive a Faxed Order Confirmation with the new
key.
4.3 Upgrade an Existing SAL Autoloader

NOTE: Early production SAL autoloaders may need new
upgrades assemblies to the interlock box, nudger and stack
increment, depending on the machine ID number.
An existing SAL autoloader to be used for a MAL system requires

the following upgrade changes:
1. Remove the engine and autoloader service covers.
2. Replace the interlock box, nudger and stack increment using
information in the Luxel V-6 CTP Engineers Reference Guide if
the configuration is for early production SAL machines.
Check that these nw assemblies operate correctly before
continuing with the upgrade.
3. Fit the supplied MSB_PWR cable (99700690) between the
interlock box (ILOCKMSB3), MSB3 (PL 31) and MSB4 (PL 31).
4. Set the new MSB3 link settings, see Section 4.5.5.1 on page 4-29.
5. MLS Autoloader: remove the autoloader top cover, MLS cassette
cover (4-off screws) and MLS door.
Replace with the supplied top cover if MLS is fitted.
6. Non-MLS Autoloader: remove the autoloader top cover and
retain.
7. Remove the lower panel.
8. Remove the autolock assembly (see Figure 4.2 on page 4-7) by
holding the posidrive at the top and loosening the rod screw
fixing underneath using a 4 mm Allen Key.
Remove the complete autolock assembly from the frame (2-off
pozi-screws).
ROD
M4 CAP HEAD SCREW
AUTOLOCK ROD SCREW
A 1 6 C
B D
2 3 4 5
FRAME
(TOP VIEW, MMI SIDE))
Figure 4.2 SAL autolock latch
9. Remove and refit sensor (AS1) with the supplied new guard, see
AS1
SENSOR
GUARD
Figure 4.3 Fitting the new AS1 sensor guard
10. Fit the supplied cassette support pads onto each side of the stack
height frame, see Figure 4.2 on page 4-7, using the existing frame
screws.
11. Fit the supplied adaptor top panel to the autoloader using the
two outside top holes (inner holes for MLS panels) and two
bottom holes, see Figure 4.7 on page 4-14.
4.4 Install the Upgrade MAL Autoloader

A MAL autoloader is shipped with the upgrade kit and is fitted
using the procedure below.
NOTE: A MAL autoloader is shipped with an adaptor top panel

already fitted.
4.4.1 Remove Autoloader and Cassette Tran-

sit Fixings
1. Remove the top interlocked cover from the autoloader.
2. Remove the nudger lift and diverter transit fixings (2-off M4).
4.4.2 Integrating the Autoloader and Engine

The autoloader and engine are integrated as follows:
1. Remove the lower front cover on the autoloader (2-off M4).
2. Detach the adaptor assembly from the shipped autoloader frame
(5-off M5 screws). See Figure 3.8 on page 3-12.
Leave the free end of the interlock cable in place on the
autoloader.
3. Mate the autoloader to the engine as follows:
A) Locate the two adaptor pins inside the two autoloader
keyholes.
LOCKING
NUT
8 mm
JACKING
BOLT
SEATING
PLATE
Figure 4.4 Adjusting the autoloader feet

4-10 INSTALLING THE MULTI -CASSETTE UPGRADE
B) Obtain the 4-off seating plates (anchor feet) from the
accessories pack and locate them underneath each
autoloader jacking bolt, see Figure 4.4 on page 4-9.
C) Raise the autoloader feet gradually (using an 8 mm
spanner) so that the two adaptor pins are touching the
bottom lip of the keyhole slot, see Figure 3.8 on page 3-12.
4. Use a spirit level on the top frame cover to check that the
autoloader is level.
5. Check that the top engine and autoloader panels are level.
6. Lock the four autoloader feet.
4.4.3 Connect the Autoloader Cables

1. 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 autoloader top cover is removed. If this cable is not fitted and
the shorting connector is removed, then the machine is in a dangerous
state for the operator.
2. V6A_CAN_AUTO: from MSB3 SK1 to MSB2 SK3. This cable is in

the Accessories pack. See Section 4.5 on page 4-11.
NOTE: The MSB PWR cable is fitted after the autofeeder has
been installed.
MSB2
MSB1
Figure 4.5 Location of MSB2
4.4.3.1 Connect the Processor Earth Cable

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

and pass one end through the cable entry slot, see Figure 4.6 on
page 4-12 (a).
5. Remove the processor side cover to gain access to the mains
electrical box.
6. Feed the cable end, marked G&J through the cable entry hole at
the back of the box.
7. Fit the cable to the earth stud shown in Figure 4.6 on page 4-12
(b).
8. Replace the processor cover.
CABLE
ENTRY
BASE
EARTH
STUD
CABLE
ENTRY
a) V-6 ENGINE SLOT
EARTH
STUD
b) G & J PROCESSOR
BASE
EARTH
STUD
c) HEIGHTS INCA PROCESSOR
Figure 4.6 Fitting the processor earth to the engine
4.4.3.3 Heights (Inca) Earth Cable Fitting

and pass one end through the cable entry slot (see Figure 4.6 on
page 4-12 (a).
4. Route the cable to the processor earth stud shown in Figure 4.6
on page 4-12 (c).
4.5 Install the MAL Autofeeder

Follow all the Installation steps in the sections above for installing
a processor, engine and autoloader. Note the following:
Before installing an autoloader, thread the 4-off cables listed
in Section 4.5.2 on page 4-16 through the autoloader cable
holes at the top input location.
Do not remove the MLS transit bolt.
Connect the Diagnostic cable between the RIP PC or laptop
and MSB 4 (PL16), see Figure 4.11 on page 4-18.
If you need to manually raise or lower the shelves then use the
procedure in Section 4.5.3 on page 4-21.
4.5.1 Integrate and Level the Autofeeder

(Basic Fit)
NOTE: A basic levelling of the two units is made before the two
units are correctly aligned for smooth cassette transfers. A fine
level check is made at the end of the alignment.
1. Before installing an autofeeder, route the 4-off cables listed in

Section 4.5.2 on page 4-16 through the autoloader interconnect
cable holes.
2. An adaptor top is already fitted to the autoloader, see Figure 4.7
on page 4-14.
Tighten the two lower screws on the adaptor top so that the
adaptor extensions are tight against their support ledges, see
ADAPTOR
ASSEMBLY
SCREW FIXING
HOLES
AUTOLOADER
Figure 4.7 Locating the top adaptor plate
3. Locate the autofeeder in its working position next to the

autoloader and adjust the four jacking feet to get the two
modules approximately level.
4. From the service end first, lift off the wooden transit block
securing the elevator to the frame.
CAUTION: Do not lift off the user end first.
NOTE: The wooden transit block under the elevator is removed

at a later stage after elevator is manually raised.
5. Position a 600 mm or more spirit level along the autofeeder

shelves to check levels in X and Y directions and adjust the level,
see Figure 4.8 on page 4-15.
6. Push the autofeeder frame up to the adaptor top so that:
the left and right hand support ledges align on the inside
face, and
the angle plates slide inside the rear part of the

autofeeder.
7. Adjust the level of the autofeeder so the adaptor plate extensions
are level with the two opposing cassette support ledges. Slide a
small metal rule along the two surfaces and check that it moves
smoothly across in both directions, see Figure 4.9 on page 4-16.
CASSETTE/TROLLEY
AUTOFEEDER
AUTOLOADER/ENGINE
AUTOLOADER/ENGINE
AUTOFEEDER
CASSETTE/TROLLEY
Figure 4.8 Levelling the autofeeder

SUPPORT SUPPORT METAL ADAPTOR

PADS LEDGE RULE EXTENSION
AUTOLOADER AUTOFEEDER
Figure 4.9 Ledges and extensions are level
8. Continue to interconnect the cable and load the software before

checking the mechanical alignment of the autofeeder and
autoloader, see Section 4 on page 4-26.
4.5.2 Connect the Autofeeder Cables

Attach the following cables betwwen the autoloader and the
autofeeder:
V6AF_Mains_Feed (99700688): this is routed to avoid signal
cables. Fit the IEC connector at the rear of the Interlock box
(ILOCK) and run along the base of the engine. Make sure the
cable is passed through the lower autofeeder hole and con-
nected to the elevator motor control assembly, see Figure 4.10
on page 4-17.
MAINS OUTPUT
TO AUTOFEEDER
Figure 4.10 Interlock box to mains connection
MSB_Power (99700690): connect the free end from the Inter-

lock box ILOCK MSB3 connector to MSB 4 (PL31). Route the
cable through the top access hole in the autofeeder.
PL7 PL9 PL12 PL14 PL21 PL23 PL24 PL25

PL19
PL26
PL18
SK3
PL30
PL6
SK2 PL29
PL5 TP3 CAN 5V
PL11
LK1 TP1 GND
SK1
PL28
LK2
PL4
PL33
PL3 PL17
PL13
PL27
PL2
PL1
PL31
PL15 PL16 PL20 PL22

PL8 PL10
Figure 4.11 MSB 1-4 connectors

EARTH WIRE
FROM AUTOFEEDER
AUTOLOADER
Figure 4.12 Fit the earth wire to SAL
V6AF_Earth (99700684): this cable is attached between the

earth fixing points on the autoloader and autofeeder, see
Figure 4.12 on page 4-19. Route the cable through the lower
access hole on the autofeeder.
V6AF_Can_Auto (99700679): connects from MSB3 (SK3) to
MSB4 (SK1).
WARNING: an earth wire MUST be fitted between the autoloader

and autofeeder.
UPPER
HOLE
TO MSB4
LOWER
HOLE
POWER
EARTH
WIRE
Figure 4.13 Routing of autofeeder cables
Check for earth continuity between the two modules.
WARNING: Make sure the cable safety labels are attached as

shown in Chapter 2.
CAN_Auto Cable (99700679) fit this cable between MSB 3

(SK3) and MSB 4 (SK1). Route the cable through the upper
access hole on the autofeeder.
4.5.3 Remove Transit Fixings Using the Brake

Override
WARNING: Keep away from moving parts on or near the scissor-
jack elevator while using this procedure. Safety features on the
autofeeder are overridden.
Use the brake override procedure below to manually raise and

lower the scissor-jack mechanism for access to the transits.
Item Required: brake override switch assembly (7A10980). This
assembly routes +24 VDC directly to the two safety solenoids and
the brake relay to release the solenoids and the motor brake.
4.5.3.1 Set up the Brake Override

1. Switch off the engine (if it is already on).
2. Connect the brake override switch as follows (see Figure 4.14 on
page 4-22):
A) Disconnect the power cable (PL31) from MSB4 and connect
it to the long cable extension of the brake override.
B) Disconnect the inline connector between MSB_DOOR
CABLE (99700704) and DOOR_LOCK (99700683) and
connect the door_lock end to the short cable extension of
the brake override.
3. Switch on the engine and put into Boot mode by pressing [Ctrl-c]
when requested. This will suppress any error messages.
4.5.3.2 Remove the Transits

1. Remove the two elevator side transits after releasing the tension
on the chain, see Section 4.5.4 on page 4-23 and Section 4.5.3.4
on page 4-23.
2. Remove the three cassette corner transits shown in Section 4.5.4
on page 4-23.
If necessary, use one of the procedures below to lower (Section
4.5.3.4 on page 4-23) or raise (Section 4.5.3.5 on page 4-23) the
elevator for accessing the cassette corner transits.
MSB_PWR CONNECT TO A
PL31
MSB4
MSB_PWR
PL1/PL2
CONNECT TO B
MSB_DOOR
INVERTER
DOOR_LOCK
BRAKE
OVERRIDE
ASSEMBLY
SWITCH
Figure 4.14 Connecting the brake over-ride assembly

4.5.3.3 Remove the Brake Override

1. Once the transits have been removed, switch off the engine.
2. Disconnect the brake override assembly and:
A) reconnect PWR to MSB4 and
B) reconnect MSB_DOOR and DOOR_LOCK cables.
3. Switch on the engine and load the LuxelDesktop application (see
Section 4.6 on page 4-31) to allow you to remove the remaining
transit fixings on the cassette and elevator.
4.5.3.4 Lower the Elevator

1. Depress the override switch and turn the elevator motor spindle
anti-clockwise to tension the chain.
2. Depress the switch briefly in short steps to release the brake and
allow the shelves to lower under their own weight.
CAUTION: Make sure the elevator does not accelerate too

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

WARNING: If the shaft spins out of control then release the
switch. Do not attempt to hold the shaft.
1. Use a tool or turn the motor shaft by hand to move the shelves up
(anti-clockwise) or down (clockwse).
2. Depress the override switch to release the brake.
3. Turn the elevator motor shaft anti-clockwise to tension the chain.
4.5.4 Remove the Transit Fixings

Remove the transit fixings on the autofeeder shown in
Figure 4.15 on page 4-24 and Figure 4.16 on page 4-25.
A) Cassette corner: remove the cassette corner bracket (2-off
screws) on each of the cassettes.
B) Elevator side: remove the 2-off elevator side brackets (4-off
screws) on each side.
C) Cassette rear: remove the 1-off (2 screws) cassette rear
bracket during the Cassette Change procedure.
CASSETTE CORNER
TRANSIT
ELEVATOR SIDE TRANSIT
Figure 4.15 Removing transit fixing (view 1)

Figure 4.16 Removing transit fixing (view 2)

4. With the system switched on and the LuxelDesktop application
loaded, use the Change Cassette procedure (see the Luxel V-6 PCI
Users Guide) to open the cassette door.
CAUTION: Do not select the TOP shelf during a Change Cassette

before removing the wooden transit block at the front of the ele-
vator.
5. Start a Change Cassette procedure for the middle shelf cassette

(2), open the cassette door and remove the cassette rear transit
fixing.
6. Remove the wooden block under the front of the elevator by
lifting up and pulling out from the user side.
7. Select the bottom cassette for a Change Cassette and remove the
transit fixings.
4.5.5 Integrate and Level the Autofeeder

(Fine Level)
NOTE: make sure all the transit fixings are removed before start-
ing the fine alignment.
In this procedure the two modules are aligned more accurately so

that cassettes move reliably to the correct mount position on the
autoloader.
1. Viewing from the top of the autofeeder, manually push the
cassette towards the autoloader. It should latch and click into
the mount position.
2. If the cassette fails to mount properly then check the cassette
alignment to ensure:
A) there are evenly matched spaces beween the cassette and
the adaptor top panel on each side, see Figure 4.17 on
page 4-27,
CHECK FOR EQUAL SPACING BETWEEN THE CASSETTE AND ADAPTOR SIDES
AUTOLOADER
ADAPTOR
ADAPTOR SIDE
SIDE
CASSETTE
AUTOFEEDER
Figure 4.17 Checking autofeeder-autoloader alignment
3. Push the cassette into the two location pins and note if the
cassette front end has to nudge in either horizontal direction to
reach the correct mount position.
NOTE: Unlatch the cassette from the autoloader by pulling back

the latch arm under the cassette base.
4. If there is slight movement then:

raise the autofeeder feet
move the autofeeder slightly in the same nudge direction

to re-align with the location pins
lower the feet on the autofeeder.

5. Repeat the steps above to check the alignment again until the
cassette latches correctly.
6. Tighten the 4-off screws on adaptor angles and the 4-off screws
on the adaptor top.
7. Check the level between the two units, see Figure 4.9 on page 4-
16.
8. Once the two modules are level, secure the two units together
with 4-off M5 x 20 cap head screws supplied in the Support Pack,
see Figure 4.18 on page 4-28.
M5 x 20 CAP HEADS
Figure 4.18 Securing the autofeeder and autoloader

4.5.5.1 MSB PCB Links

The two links located on the MSBs (1 to 4) are set as shown
in Table 4.1 on page 4-29:
1. LK1: CAN Terminator.
2. LK2: Reset Terminator.
See also Figure 4.11 on page 4-18 showing the location of the
links.
Table 4.1 MSB 1 to 4 Link settings

PCB V-6 Fully-Automatic V-6 Fully-Automatic
(SAL) (MAL)
Link 1 Link 2 Link 1 Link 2
MSB 1 Not Fitted Not Fitted Not Fitted Not Fitted
MSB 2 Not Fitted Not Fitted Not Fitted Not Fitted
MSB3 Fitted Fitted Not Fitted Not Fitted
MSB4 N/A N/A Fitted Fitted
4.5.6 Levelling the Trolley

1. Remove the cassette lid and lift out the two polystyrene blocks.
2. Remove the tape holding down the cassette lid flap.
3. Use Cassette Change to remove a cassette on to the trolley.
4. Load the cassette with plates.
5. Adjust the trolley feet so that the side bumpers are level with the
guides shown in Figure 4.19 on page 4-30.
6. Dock the trolley, check that the docking light is on and push the
cassette forward until it latches.
NOTE: Unlatch the cassette from the autoloader by pulling back

the latch arm under the cassette base.
7. Repeat the procedure for the other shelves.

8. Two man lift: fit the top autofeeder pod and secure into position
at each corner (4-off screws in support pack).
9. Refit all the covers.
BUMPER GUIDE
CASSETTE BUMPER
BUMPER GUIDE
CASSETTE BUMPER
Figure 4.19 Levelling the trolley

4.6 Commissioning the Upgrade

4.6.1 Enable the Machine Type
This procedure sets the machine type.
1. Refit all the doors and covers.
2. Connect a PC terminal to the engine RS232 Diagnostics output or
open HyperTerminal on the RIP PC.
3. Power up the engine and press [ctrl-c] after the first message to
stop the boot. Note that this message appears very quickly after
pressing the Power On switch. The display indicates the system
remains in Boot mode.
If the Formatter Board is running PHASE 10 (or higher), enter:
main> machine 13
then continue from step 7.
4. If the Formatter Board is running PHASE 8 or 9 then enter:
main>machine
5. Use the left arrow [<-] to select Luxel V_6 MC CTP.

6. Enter [Return] to obtain the main> prompt.
7. Reboot the engine and stop at the first [Ctrl-c] request to remain
in Boot mode.
4.6.2 Update the Licences

New licences, created as part of the autoloader upgrade order,
are installed using the procedure in the Luxel V-6 CTP Installation
Manual.
All new hardware upgrades to an existing machine are supplied
with their own Installation Notes as part of the kit.
The procedure for obtaining licence keys for all newly ordered
options on an installed machine is the same as a full installation,
except that the Distributor will also receive a Faxed Order
Confirmation with the new key.
For a single- and multi-cassette system there must be valid
licences for options:
Manual to Semi-Auto.
Semi-Auto to SAL.
Manual to MAL.
Semi-Auto to MAL.
SAL to MAL.
1. Check the current set of options by selecting Engine Info from the
RUN or PAUSE keypad.
Select Review Licence Options to check installed licences.
4.6.2.1 Installing Licences

Installation Report from Installation Data for the customer.
2. Open the Report to display a list of licence keys for the
configuration.
NOTE: One key may include all the ordered options for an
upgrade.

the PCI, and press Confirm. See Figure 4.20 on page 4-33.
ENTER KEY
CONFIRM
4. Make sure the customer is aware of their new keys by supplying a

text file copy.
5. After installing new licence(s), reboot the engine.

1. Set up the NVRAM parameter:
>snv HAS_PROCESSOR 1
2. Restart the LuxelServer and reboot the platesetter.
3. Ensure that the processor comms preference is enabled from the
PCI menu.
4. Check that the processor and engine are able to communicate by
entering:
0.15 = 150
0.20 = 200
0.24 = 240
0.30 = 300.
6. Check in the processor display that the processor pre-heat
temperature zones change as plates of different thickness are
changed:
0.15 = P1 (G&J)
0.20 = P2 (G&J)
0.24 = P3 (G&J)
0.30 = P4 (G&J).
7. Check the distance and speed parameters for the processor while
the test plates are running.
4.6.4 Check Cover Interlocks (Autoloader)

See also Section 2.3 on page 2-15.
Autoloader cover open when the environ command is run.
laser light
spinner
vacuum pump.
spinner stops
laser light
vacuum pump.
579: autoloader top cover removed.
4.6.5 Run Test Plates

See the Luxel V-6 Series Engineers Reference Guide.
1. Load the cassette with a plate type and size that have previously
been used with the old manual engine.
2. Output a single plate from Media Tools to check that the
autoloader, engine and processor media handling are correct.
3. Output a stock image and to check the engine and processor
outputs.
Check for image skew and image start positions.
4. Output customer job images to check the RIP.
COMMISSIONING THE LUXEL V-6
UPGRADE
This chapter describes how to test, set up and demonstrate a manual
and semi-automatic platesetter (without a punch) as a working unit for
the customer.
Starting to Commission the Platesetter .................................................... 5-1
Initial Software Checks and Setups........................................................... 5-2
Setting up Optics and Imaging................................................................... 5-6
Checking Plate Output (Without a Punch) .............................................. 5-10
5.1 Starting to Commission the Platesetter

System commissioning is divided into stages:
1. Initial machine and software checks and setups:
diagnostics menu and engine clock
power supply
interlock doors and covers
traverse level check
plate feed
processor setup.
2. Optics setups: the optics system is fully tested at the factory
5-2 C OMMISSIONING THE LUXEL V-6 U PGRADE
but needs to be configured for the installation.

3. Platesetter plate handling: plates are transported through the
system and adjustments are made to handling mechanisms on
each of the modules.
4. Install and commssion the RIP: install and launch the RIP soft-
ware.
5. Run customer jobs and demonstrate product: the complete
platesetter system is checked with job images downloaded
from the RIP.
Each stage is carried out in the recommended order described in
this chapter using additional information from the:
PCI and/or MMI Users Guide (if the MMI option is fitted).
Engineer's Reference Guide.
RIP Operators Manual (for the appropriate application).
RIP/server/network/PC documentation.
Processor documentation.
5.2 Initial Software Checks and Setups

5.2.1 Open Main Diagnostics and Check
Engine Clock
See the Luxel V-6 CTP Engineer's Reference Guide.
To run all the procedures in this chapter connect a PC or laptop
terminal to the RS232 Diagnostics connector on the Engine or use
the RIP/GUI PC if there is a Diagnostics cable connection to the
Engine.
1. Switch on the platesetter.
2. Open the HyperTerminal window (for instance, on the PC select):
StartProgramFUJIFILM Electronic Imaging LtdRecorder Util-
ity Tool SetHyperTerminal/Diagnostics Terminal
3. Set the Properties options for the platesetter comms link to the
terminal as follows:
Connect: COM1 or 2.
LUXEL V-6 CTP 5-3
Settings: Autodetect.
Configuration: 9600 bits per sec; 8 data bits; No parity;

1 Stop bit; No flow control.
32-bit display.
4. If you need to transfer scrolled text to a selected file from the
HyperTerminal window, switch on Capture Text from the Transfer
menu and enter a filename for saving the captured text.
5. From the (Main>) prompt open the Diagnostics menu.
main>diagnostics
Enter password: *** (if requested)
6. Check the current time and date on the Engine using:
service/time/now
7. If it is incorrect, then set the time and date as follows:
service/time/set_time YY MM DD d hh mm ss
where:
YY = 2 digit year
MM = month
DD = day of month
d = day of week (1 is Monday)
hh = hour
mm = minute
ss = seconds.
5.2.2 Check Power Supply Voltages

Check the power supply voltages by running:
All voltage readings should be within +/- 5% of the nominal
voltages (see the Luxel V-6 CTP Engineers Reference Guide).
5.2.3 Check Cover Interlocks


Autoloader cover open.
spinner
vacuum pump
compressors.
spinner stops
laser light
vacuum pump
compressor.
579: autoloader top cover removed
Error code 577 indicates that the interlock system has failed. Run
the following utility to check for the cause:
LUXEL V-6 CTP 5-5
5.2.4 Check Plate Feeds

1. Clean the Engine and plate loading platform.
2. Load and eject a plate into the drum using the Media Tools
option from the MMI (if fitted) or the PCI. You will need to create
new media from the PCI before it can be selected from the MMI
or the PCI. Check the following:
A) The plate enters the drum without damage.
B) The interleaf sheet enters the bin (autoloader only).
C) The plate conforms without damage at the registration
pins and pull bar shoes.
D) The plate exits the drum without damage.
E) The plate transfers to the processor without damage or
skewing.
F) The plate is not scratched on either side and the edges are
not damaged.
3. If any of the above checks fails, refer to the Engineer's Reference
Guide for details on how to adjust mechanisms.

1. Ensure that the link is enabled from the PCI menu.
2. Check that the Processor and Engine are able to pass messages by
entering:
0.15 = 150
0.20 = 200
0.24 = 240
0.30 = 300.
4. Check that the processor pre-heat temperature zones change as

plates of different thickness are changed:
0.15 = zone 1
0.20 = zone 2
0.24 = zone 3
0.30 = zone 4.
5.3 Setting up Optics and Imaging

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

This procedure allows you to verify and change the NVRAMs for
the Beam Converter Focus (BCF) mechanism so that it moves to
the optimum focus position for all resolutions (res) and plate
thicknesses.
1. The Auto Focus check (see Table 5.1 on page 5-7) runs two sets of
test strips called:
1. Focus V (vertical)
2. Focus H (horizontal).
Focus strips are only run for 96res; the settings for the 48 res are
calculated from the 96res value.
2. Use the largest available plate for these checks, making sure the
minimum plate height is 600 mm.
3. Open the test pattern setup screen:
main> diagnostics/service/optics/mmi
4. Ensure that the ND value in the Final Values table for 96res is 85.
5. Expose 2 blocks of 13 test strips using the Auto Focus macro. This
operates with the values shown in Table 5.1 on page 5-7 below.
NOTE: Strips are exposed in order from left to right on the plate.
LUXEL V-6 CTP 5-7
Table 5.1 Beam focus check

RUNS TEST STRIPS:
AUTO FOCUS MACRO: Focus V Focus H
Set Defaults? Yes N/A
Scan Start Posn (mm) 10 N/A
Strip Width (mm) 8 8
Start Value 900 900
Step Value 50 50
Number of Steps 13 13
Resolution 96 l/mm 96 l/mm
Pattern Type Vert Hor
Lines 2on 2off 2on 2off
Start Scan Yes Yes
6. Eject and process the plate.

7. Check the two sets of strips: Using a densitometer, find the
lightest density strip for each focus test strip shown in Figure 5.1
on page 5-9. This should be in the range of 900 to 300. Check
the top and bottom of the plate, and ensure that:
A) The 2 lightest values, top, middle and bottom, from each
block of test strips should be within 3 strips of each other.
Obtain a single average value.
B) The average value of the Vertical and Horizontal strips,
top, middle and bottom, should be within 3 strips of each
other.
8. Enter the 96 value into the 2400, 96, 100, 3600 and 144 positions
for the plate thickness used.
9. Use the following examples to obtain the focus value for 48res:
If the 96res has a value of, for example, 750 or 600 or 400
disregard the - (minus) attached to the 96res result and add 2900
to the 96res value to obtain the 48res value. For example:
750 + 2900 = 3650
600 + 2900 = 3500

400 + 2900 = 3300
10. Set the 1200, 48 and 50res focus positions to be the same for all
plate thicknesses.
11. Save the focus step positions in the Final Values table.
12. Find the focus step positions for each remaining plate thickness
by calculating the offset values from Table 5.2 on page 5-8 as
follows:
A) for instance, if a 96res 0.15 plate gives 600, then a 0.30
plate gives 525, or
B) for instance, if a 96res 0.24 plate gives 750, then a 0.15
plate gives 795.
:
Table 5.2 Focus positions for plate thickness at 96res

Tested Plate Offset for Focus Offset Value:
Thickness (mm): Plate:
0.15 0.2 Add 25

0.24 Add 45
0.3 Add 75
0.2 0.15 Subtract 25
0.24 Add 20
0.3 Add 50
0.24 0.15 Subtract 45
0.2 Subtract 20
0.3 Add 30
0.3 0.15 Subtract 75
0.2 Subtract 50
0.24 Subtract 30
LUXEL V-6 CTP 5-9
NOTE: The focus offset is 1 step per 2 m change in the plate

thickness. Thinner plates should have lower focus numbers at
96res. At 48res, all focus numbers are the same since the depth
of the focus is much higher.
BLOCK OF TOP VALUE

TEST STRIPS
BOTTOM VALUE BEST AVERAGE FOCUS MIDDLE VALUE
Figure 5.1 Selecting best block focus test strip
13. If any of these focus conditions cannot be met then:

A) Try a different value for ND and check the processor setup.
B) Finish the required setups as well as possible and check the
resulting quality using an S&T page. If it is unsatisfactory
and cannot be improved, consult FFEI Customer Services.
14. Store all focus positions for all resolutions in NVRAM using the
Final Values menu.
5-10 COMMISSIONING THE LUXEL V-6 U PGRADE
5.4 Checking Plate Output (Without a Punch)

See the Luxel V-6 CTP Users Guide and Engineers Reference
Guide.
These procedures apply to a platesetter without a punch and
check for:
Image skew accuracy - see Section 5.4.1 on page 5-10.
Image start/edge accuracy - see Section 5.4.2 on page 5-11.
Image base offset - see Section 5.4.3 on page 5-12.
5.4.1 Check Image Skew Accuracy

Use 305 mm registration pin centre points for these skew
measurements as plate edge quality varies across the plate.
1. Expose a tint on a 765 mm x 686 mm plate, or use the largest
plate available.
2. Measure reference lines A and B using, at least, a x50 eyeglass
with a measurement graticule fitted, see Figure 5.2 on page 5-11.
3. Check that the difference between the two lines is less than or
equal to 25 microns.
4. Expose and measure 4 plates and check that repeatability is less
than or equal to 25 microns.
5. A possible cause of error is a poor pullbar adjustment.
Information on the pullbar adjustment is in the Luxel V-6 CTP
Engineers Reference Guide.
LUXEL V-6 CTP 5-11
CENTRE OF
PLATE
305 mm (STANDARD)
A B
IMAGE
PLATE
Figure 5.2 image skew check
5.4.2 Check Image Start and Edge Accuracy

1. Expose a tint on a 765 mm x 686 mm plate, or the largest plate
available on-site.
2. Check that the distance between the image start positions and
plate edge is as shown in Figure 5.3 below. Measure from the
registration pins for the image top offset, and 67 mm down from
the plate top edge for the image side offset position on the
lefthand side.
A B
2 mm ( +- 25 m)
67 mm
2 mm
( +- 25 m)
IMAGE
PLATE
Figure 5.3 Edge detect and image accuracy
5.4.3 Set Image Base Offset

NOTE: The image traverse centre position is factory-set and

should not need to be adjusted during an installation.
Information on a field adjustment, if required, is available in the
Luxel V-6 CTP Engineer's Reference Guide.
This procedure adjusts the non-imaged area at the top of the

plate.
1. Expose a tint image from the PCI Diagnostics menu on a 765 mm x
686 mm plate, or the largest plate available on-site.
2. Check for the default area shown in Figure 5.4 on page 5-13.
3. Modify the value of the IMAGE BASE OFFSET until the top of the
plate to the image is 2 mm 25 m. Use the following menu:
diagnostics/service/optics/mmi
Enter Machine Setup and adjust the value of the Image Base
Offset (Microns).
LUXEL V-6 CTP 5-13
To move the image nearer the registration pins, reduce the

value.
To move the image away from the pins, increase the value.
START OF
SCAN START
SCAN
IMAGE_BASE_ POINT
OFFSET = 2 mm
( +- 25 m)
IMAGE
PLATE
Figure 5.4 Setting the image base offset
5.4.4 Set Image Edge Sensor Offset

1. Open the optics_mmi setup screen from:
main>diagnostics/service/optics/mmi
2. Run a test pattern with the Scan Start position as 0 mm.
3. Eject and process the image and check that it is exactly 2 mm from
the lefthand edge of the plate, measured 67 mm down from the
top as shown in Figure 5.3 on page 5-12.
4. If it is not then find the current parameter Edge Sensor Offset
value (in microns) as follows:
diagnostics/service/optics/mmi
Using Machine Setup, find the current setting for Edge Sensor
Offset.
5. If the image is more than 2 mm from the plate edge then
decrease the parameter value; if it is less than 2 mm then increase
the parameter value.
Repeat these steps until the edge of the plate to the image start
position is 2 mm +/- 25 m.

Luxel v6 2

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LUXEL V-6 CTP FULLY-AUTOMATIC

Electromagnetic Compatibility Notice - USA

Electromagnetic Compatibility Notice - Europe

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

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

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

This equipment conforms to the requirements of EC directives:

73/23/EEC - Low Voltage Directive

89/336/EEC - EMC Directive.

About this Manual

Manual to a Fully-Automatic Single-Cassette (SAL).

Semi-Automatic to a Fully-Automatic Single-Cassette (SAL).

Manual to a Multi-Cassette (MAL).

Semi-Automatic to a Multi-Cassette (MAL).

Fully-Automatic (SAL), with or without MLS, to a Multi-Cassette (MAL).

Engineers are recommended to refer to the safety practice information in Chap-

Chapter 2 Safety on the Luxel V-6 CTP

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

Chapter 3 Installing the Single-Cassette Upgrade

3.3 Removing the Plate Lifter (Input Platen) ........................................ 3-4

Chapter 4 Installing the Multi-Cassette Upgrade

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

Chapter 5 Commissioning the Luxel V-6 Upgrade

1.1 Before Starting the Upgrade

This installation manual explains how to upgrade a currently

Figure 1.1 Luxel V-6 semi-automatic

Figure 1.2 Luxel V-6 single-cassette (SAL)

Figure 1.3 Luxel V-6 multi-cassette (MAL)

1.1.1 Manual to Semi-Automatic

1.1.2 Semi-Automatic to Fully-Automatic

1.1.3 Manual to Fully-Automatic (SAL)

1.1.4 Manual to Multi-Cassette (MAL)

1.1.5 Semi-Automatic to Multi-Cassette

1.1.6 Single-Cassette (SAL) to Multi-Cassette

1.2 Unpacking the Upgrade Kit

1.2.2 Inspection of Boxes

Figure 1.4 Mishandling indicators

NOTE: If the Tip or Drop indicators on the engine are tripped

Units may be removed from their box only by an approved

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

1.2.3 Unpacking the Modules

CAUTION: Two people are required to manoeuvre the autoloader

CAUTION: Five people are required to lift the processor. Four to

CAUTION: Modules should only be unpacked after a 24 hours

Unpack each box using the instructions attached to the outside of

FOAM FORK STOP BEARING FORK STOP FOAM

FORK REMOVEABLE FORK

Figure 1.5 Unpacking the module boxes

CAUTION: Check that the anchor feet are fully retracted.

NOTE: There should be an acclimatisation period of 24 hours

Table 1.1 Upgrade Accessories pack (V-6 to SAL)

2 Engine firmware/PCI and RIP

3 Upgrade Installation Manual

4 Processor comms cable (manual to semi only)

5 Processor buffer and screws (manual to semi only)

6 Output stretcher (manual to semi only)

12. Arrange locally for the removal of disposable packaging

1.2.4 Unpacking the Processor

Use the supplied Installation Manual to obtain information on

1.3 Handling the Equipment