User Guide

English

Lotem 400 Family

399Z1N136C www.creo.com
Lotem 400 Family

User Guide
Copyright
Copyright © 2003 Creo Inc. All rights reserved.
No copying, distribution, publication, modification, or incorporation of this document, in whole or part, is
permitted without the express written permission of Creo. In the event of any permitted copying, distribution,
publication, modification, or incorporation of this document, no changes in or deletion of author attribution,
trademark legend, or copyright notice shall be made.
No part of this document may be reproduced, stored in a retrieval system, published, used for commercial
exploitation, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the express written permission of Creo Inc.
This document is also distributed in Adobe Systems Incorporated's PDF (Portable Document Format). You may
reproduce the document from the PDF file for internal use. Copies produced from the PDF file must be
reproduced in whole.
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Trademarks
The Creo wordmark, Creo logo, and the names of the Creo products and services referred to in this document are
trademarks of Creo Inc.
Adobe, Acrobat, and the Acrobat logo are registered trademarks of Adobe Systems Incorporated, and are
registered in the U.S. Patents and Trademark Office and may be registered in other jurisdictions.
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Computer, Inc.
Microsoft, Windows, Windows 2000, and Windows NT are trademarks or registered trademarks of Microsoft
Corp.
Xerox is a registered trademark of Xerox Corp.
Other brand or product names are the trademarks or registered trademarks of their respective owners.
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FCC Compliance
The Creo equipment referred to in this document complies with the requirements in Part 15 of FCC Rules for a
Class A computing device. Operation of the Creo equipment in a residential area may cause unacceptable
interference to radio and TV reception, requiring the operator to take whatever steps are necessary to correct the
interference.
. ...................................................................................................

Limitation of Liability
The product, software or services are being provided on an "as is" and "as available" basis. Except as may be stated
specifically in your contract, Creo Inc. expressly disclaims all warranties of any kind, whether express or implied,
including, but not limited to, any implied warranties of merchantability, fitness for a particular purpose and non-
infringement.
You understand and agree that Creo Inc. shall not be liable for any direct, indirect, incidental, special,
consequential or exemplary damages, including but not limited to, damages for loss of profits, goodwill, use, data
or other intangible losses (even if Creo has been advised of the possibility of such damages), resulting from: (i)
the use or the inability to use the product or software; (ii) the cost of procurement of substitute goods and
services resulting from any products, goods, data, software, information or services purchased; (iii) unauthorized
access to or alteration of your products, software or data; (iv) statements or conduct of any third party; (v) any
other matter relating to the product, software, or services.
 The text and drawings herein are for illustration and reference only. The specifications on which they are based
are subject to change. Creo Inc. may, at any time and without notice, make changes to this document. Creo Inc.,
for itself and on behalf of its subsidiaries, assumes no liability for technical or editorial errors or omissions made
herein, and shall not be liable for incidental, consequential, indirect, or special damages, including, without
limitation, loss of use, loss or alteration of data, delays, or lost profits or savings arising from the use of this
document.
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Patents
This product is covered by one or more of the following U.S. patents:
RE37,376 5,325,217 5,532,728 5,742,743 5,996,499 6,158,345 6,353,216
4,558,302 5,339,176 5,561,691 5,764,374 5,998,067 6,159,659 6,366,339
4,743,091 5,343,059 5,568,595 5,764,381 6,003,442 6,164,637 6,371,026
4,992,864 5,355,446 5,576,754 5,771,794 6,014,471 6,180,325 6,377,739
5,049,901 5,359,451 5,579,115 5,785,309 6,016,752 6,181,362 6,387,597
5,079,721 5,359,458 5,592,309 5,813,346 6,031,932 6,181,439 6,396,422
5,103,407 5,367,360 5,594,556 5,818,498 6,043,865 6,186,068 6,396,618
5,111,308 5,384,648 5,600,448 5,854,883 6,060,208 6,189,452 6,407,849
5,113,249 5,384,899 5,608,822 5,861,904 6,063,528 6,191,882 6,414,755
5,122,871 5,412,491 5,615,282 5,861,992 6,063,546 6,204,874 6,422,801
5,124,547 5,412,737 5,625,766 5,875,288 6,072,518 6,208,369 6,435,091
5,132,723 5,420,702 5,636,330 5,894,342 6,090,529 6,214,276 6,441,914
5,150,225 5,420,722 5,649,220 5,900,981 6,096,461 6,217,965 6,450,092
5,153,769 5,459,505 5,650,076 5,934,196 6,098,544 6,260,482 6,456,396
5,155,782 5,473,733 5,652,804 5,942,137 6,107,011 6,266,080 6,476,931
5,157,516 5,481,379 5,680,129 5,946,426 6,112,663 6,266,134 6,477,955
5,208,818 5,488,906 5,691,823 5,947,028 6,115,056 6,267,054 6,509,903
5,208,888 5,497,252 5,691,828 5,958,647 6,121,996 6,268,948
5,247,174 5,508,828 5,696,393 5,966,504 6,130,702 6,283,589
5,249,067 5,509,561 5,699,174 5,969,872 6,134,393 6,295,076
5,283,140 5,517,359 5,699,740 5,973,801 6,136,509 6,299,572
5,291,273 5,519,852 5,708,736 5,986,819 6,137,580 6,318,266
5,323,248 5,526,143 5,713,287 5,995,475 6,147,789 6,352,816
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creo Inc.
3700 Gilmore Way
Burnaby, B.C., Canada
V5G 4M1
Tel: 1-604-451-2700
Fax: 1-604-437-9891
http://www.creo.com
399Z1R513A
Revised June 2003
Contents
Using This Manual vii
Scope of This Manual ............................................................................................................................. viii

1 Introduction 1
Lotem 400 Overview ................................................................................................................................ 2
Platesetter Front View............................................................................................................................... 3
Platesetter Rear View................................................................................................................................ 4
Typical Customer Site Configuration ......................................................................................................... 5
Data and Communication Flow ................................................................................................................ 7
Turning the Platesetter On and Off ........................................................................................................... 8

2 PC Controller User Interface 11

Overview ................................................................................................................................................ 12
User Interface ......................................................................................................................................... 13
Status Indicator ...................................................................................................................................... 14
Operation Toolbar .................................................................................................................................. 15
Routine Functions Menu .................................................................................................................. 15
Utilities Menu .................................................................................................................................. 17
Settings Menu ................................................................................................................................. 19
Stop button ..................................................................................................................................... 19
Online Machine View ............................................................................................................................. 20

3 Plate Handling 23
Media Definition..................................................................................................................................... 24
Loading Plates ........................................................................................................................................ 26
Loading Plates via the Workstation .................................................................................................. 26
Loading Plates Manually .................................................................................................................. 29
Plate Geometry....................................................................................................................................... 30

4 User Troubleshooting 33
Generic Troubleshooting Questions ........................................................................................................ 34
Startup Problems .................................................................................................................................... 35
PC Does Not Boot............................................................................................................................ 35
Windows Does Not Launch.............................................................................................................. 35
Windows Does Not Start.................................................................................................................. 36
Calling Response Center For Support...................................................................................................... 36
Plate Loading Failure............................................................................................................................... 37
Releasing Stuck Plates...................................................................................................................... 37
Double Loading ............................................................................................................................... 41
vi Lotem 400 Family User Guide

Punch is Stuck ................................................................................................................................. 43

Drum Related Errors ........................................................................................................................ 44
Error Message: Plate Did Not Reach Punch Position.......................................................................... 45
Error Message: Vacuum Did Not Grab Plate ..................................................................................... 46
Error Message: Drum Fly-off ............................................................................................................ 47
Error Message: Illegal Plate Size ....................................................................................................... 48
Error Message: Illegal Gripper Width................................................................................................ 48
Plate Unloading Problems....................................................................................................................... 49
Plate Does Not Unload..................................................................................................................... 49
Unload Failure After Plate Restart .................................................................................................... 51
Exposure Failure Problem........................................................................................................................ 51
Exposure Does Not Start .................................................................................................................. 51
Communication Problems with TSP Board .............................................................................................. 52

Index 53
Using This Manual
Scope of This Manual........................................................................viii
viii Using This Manual

Scope of This Manual

The Lotem 400 Family User Guide provides you with the basic information
you need to begin production with the Lotem 400 platesetter.
This guide includes two main parts, as detailed below.
Note: Lotem 400 Family in this document refers to the Lotem 400 and the
Lotem 400 Xpose. Unless otherwise specified, Lotem 400 refers to both
machines.

Lotem 400 platesetter and PC Controller user interface

• Introduction to Lotem 400 platesetter
• Getting started
• PC Controller user interface
• Plate handling
If you are running a Brisque to Lotem 400 workflow, please see the Brisque to
Lotem Family Connectivity User Guide, 399Z3R084A.

For a complete description of the Brisque functionality, see the Brisque User
Guide version 4.0:
Part 1 399Z50677D
Part 2 399Z50678D
Part 3 399Z51124C
Part 4 399Z51956B

If you are running an Xpose to Lotem 400 workflow, please see the Lotem 400
Xpose User Guide.

The safety precautions that must be followed when using the Lotem 400
platesetter are detailed in a separate document. See Lotem 400 Family Safety
Precautions for User, 653-00275A.

For details regarding the MCU for Lotem 400 see MCU for 400 Family User
Guide, 653-00118A.
Introduction
Lotem 400 Overview ...........................................................................2

Platesetter Front View .........................................................................3

Platesetter Rear View ..........................................................................4

Typical Customer Site Configuration....................................................5

Data and Communication Flow ...........................................................7

Turning the Platesetter On and Off......................................................8

2 Chapter 1 – Introduction

Lotem 400 Overview

The Lotem 400 platesetter is a Creo thermal imaging platesetter. It
represents state-of-the-art technology within all operational systems, and
features a technological breakthrough in the form of a multi-beam,
variable resolution thermal imaging head. Within the footprint of a typical
4-page imagesetter, the Lotem 400 platesetter with optional multi cassette
unit (MCU) provides full automation including slip sheet removal,
customized plate punching, and plate loading/unloading. It has a fast
rotating external drum and a thermal imaging head.
The thermal imaging head inside the Lotem 400 platesetter is comprised of
a 24 laser beam array operating at a wavelength of 830 nanometers.
Individual beams are precisely positioned using a self calibrating
alignment configuration, and this allows for continuously variable
imaging resolutions.
A significant and unique feature of the Lotem 400 platesetter is dynamic
drum balancing which guarantees rotational stability of the external drum.
The supported plate size range, around the drum x along the drum, is from
minimum 311 x 228 mm (12.25 x 9 inch) up to maximum 622 x 750 mm
(24.5 x 29.5 inch).
To allow for variable resolution imaging, drum rotation speed is
programmed to vary proportionally with the output resolution. This
particular feature is unique to Lotem 400 platesetter, and ensures
optimized imaging speeds based on output parameters.
The Lotem 400 platesetter front end is the Brisque or Prinergy. In addition
to standard Brisque Impose features, special features for CTP users, such as
fast plate remake and back/front preview were added. The Lotem 400
platesetter system can accept data from any standardized digital file format
including PostScript™, EPSF, PDF™, TIFF-IT, and CT/LW files.
Platesetter Front View 3

Platesetter Front View

Front door

Right side
door

Loading tray

Figure 1: Lotem 400 platesetter (manual) front view

Loading tray – for loading a plate into the platesetter.

Front door – opening is controlled from PC Controller monitor.

Right side door – access to electronic box and PC Controller.

The Lotem 400 is now available with a multi cassette unit (MCU) for automated
loading. For details see MCU for Lotem 400 Family User Guide, 653-00118A.
4 Chapter 1 – Introduction

Platesetter Rear View

Plate exit Rear door

2 on/off
pushbuttons

Main circuit breaker

Figure 2: Lotem 400 platesetter rear view

Rear door – opening is controlled from PC Controller monitor.

Plate exit – through which plates are unloaded after processing.

On/Off pushbuttons – to power up and shut down the platesetter.

Main circuit breaker – before you power on the platesetter, make sure main
circuit breaker is on (set to 1). For total disconnection from the mains
supply, set the main circuit breaker to 0.
Typical Customer Site Configuration 5

Typical Customer Site Configuration

A typical customer site configuration with the Lotem 400 platesetter is
shown below.
Plate room

Workflow PC controller
workstation monitor

Conveyor

Lotem 400 Processor

Figure 3: Typical configuration at customer site

6 Chapter 1 – Introduction

The platesetter room may include:

• Lotem 400 platesetter
• PC Controller monitor; the user interface of the PC Controller that
controls the platesetter operation.
• Workflow workstation; jobs for the Lotem 400 platesetter are processed
by the workstation.
• Conveyor; moves the unloaded plates to the Processor.
• Processor; option not supplied by Creo and intended for plates that
need processing after expose.

Note: The Plate stacker (for collecting unloaded plates) and Pre-heat oven (for
plates that require heating), not supplied by Creo, are not shown in the figure.
Data and Communication Flow 7

Data and Communication Flow

Job data is sent from the workstation, which is connected to the PC
Controller. The figure below shows the data and communication flow
between the workstation and the platesetter.

PC controller
monitor

Lotem 400
Data cable (TSP)

Point to point

Data from prepress

Workflow
workstation Network TCP/IP
100B/T

Figure 4: Communication & data flow between platesetter & workstation

8 Chapter 1 – Introduction

Turning the Platesetter On and Off

To turn on the Lotem 400 platesetter:
Important: When power is interrupted, the platesetter shuts down. To
continue working when normal power returns, you must press either of
the two yellow on/off pushbuttons twice (once to “turn off” the
platesetter and once to turn it back on) as shown in Figure 2 on page 4.
The pushbutton lights up and the platesetter restarts.

Note: Turn on the platesetter before turning on the workflow workstation.

1. Check the air pressure gauge (see figure below) in the air pressure unit.
Make sure the air pressure is 6 ATM (88 psi).

Figure 5: Air Pressure unit

2. Make sure the main circuit breaker is on, that is, set to 1 (see Figure 2
on page 4).
3. On the rear panel, press the two (2) on/off pushbuttons so that they
are both lit (see in Figure 2 on page 4).
4. Press the on/off pushbutton on the PC Controller monitor.
Turning the Platesetter On and Off 9

5. Double-click the Lotem400 icon on the PC desktop.

6. Turn on the workflow workstation.

To turn off the Lotem 400 platesetter:

1. In the PC Controller software, click Routine Functions.
2. From the Routine Functions menu, select Shut Down.
3. In the Confirm message, click Shut Down.

4. From the Start menu of your Windows, click Shutdown.

5. When the message It is safe to turn off your computer
appears, press the on/off pushbutton on the rear panel of the
platesetter.
PC Controller User
Interface
Overview ..........................................................................................12

User Interface ...................................................................................13

Status Indicator.................................................................................14

Operation Toolbar .............................................................................15

Online Machine View........................................................................20

12 Chapter 2 – PC Controller User Interface

Overview
The PC Controller monitor is your interface with the Lotem 400
platesetter; it monitors the platesetter operation, is constantly updated
with the machine status and provides machine information. The
platesetter is controlled by the PC Controller located inside the platesetter;
the monitor resides on a nearby table, as shown in Figure 3 on page 5. The
job data is sent from the workstation, that is connected to the PC
Controller (see Figure 4 on page 7).

Figure 6: PC Controller monitor

User Interface 13

User Interface
The PC Controller monitor is your basic working area, where the
application indicators, buttons, popup menus and windows appear.
The workflow-oriented platesetter user interface is intuitively designed,
and minimal computer knowledge is required. The following features
support this design:
• Color-coded Status indicator indicates the machine status. For
example, if a problem occurs while you are away from the monitor
checking exposed plates, the problem indications on the screen are
visible from a distance.
• Large interface indicators can be seen from a distance, so you can be
alerted even when working away from the monitor.
• Monitor screen is divided into functional areas, as shown in the Main
window figure below.

Status indicator Operation toolbar

Interlock Message
indicator area

Online machine view

Figure 7: Main window areas

14 Chapter 2 – PC Controller User Interface

Status Indicator
The Status indicator is fairly large and color-coded for easy identification.
The indicator updates you on machine status even when you are
performing tasks away from the monitor. For example, you can easily see
when the Status indicator changes to Attention.
Start up (green) – machine is performing start up. All machine
components go to Home position.

Off-line (gray) – like Ready, but you cannot expose plates or run
calibration tests; all other functions are available. After Start up and Stop,
the machine automatically goes to Off-line. Click On-Line button on the
Routine Functions menu to set machine to Ready.
Ready (blue) – the machine is ready for operation and in On-Line mode;
you may load a plate and begin the expose job.

Working (green) – the machine is busy exposing the current job. While the
machine is working, you can place another plate on the loading tray or
send additional jobs from the workstation.
Attention (red) – the machine has stopped working and requires your
intervention, or has encountered a problem that requires servicing. A
message appears in the message area and normal operation resumes only
after the problem is solved.
Service (purple) – a door is open or a panel was removed (the Interlock
indicator appears on the Main window) or the machine is being serviced.
If a door is open, the Online machine view shows the open door.
Operation Toolbar 15

Operation Toolbar
The Operation toolbar to the right of the Status indicator is used to access
all the operational options required when working with the platesetter PC
Controller application. The Operation toolbar includes the Routine
Functions, Utilities and Settings buttons used to open the relevant menus
and the Stop button, as described below.

Routine Functions Menu

Click the Routine Functions button to open the Routine Functions menu.
The menu includes operations that are routinely performed by the user
when working with the machine, as described below.

Sub-menu option Description

Open Front Door

1. Click this button to open the front door.
2. The door locking mechanism is released for 30 seconds. During
these 30 seconds push the door slightly inward.
3. The door releases. Lift the door to open it completely.
When the front door is open, the safety interlocks are activated. As a
result, machine systems such as drum motor and laser system do not
operate. The machine is in Service mode (Status indicator is purple) and
the Interlock indicator appears below the Status indicator with the name
of the open door.
Note: You can interactively open the door by clicking on the front door in the
Online machine view

Open Rear Door

The rear door opening is similar to opening the front door.
16 Chapter 2 – PC Controller User Interface

Sub-menu option Description

Unload Plate
This operation is available only when there is a plate on the drum and the
machine is not working.

In normal operation this option is not used since plate unloading is

automatic. However, if the plate was not loaded properly or the expose
process was not completed, you can manually initiate plate unloading.
Click Unload Plate.
Messages
Click Messages to open the Message dialog box. When problems are
encountered during machine operation, error messages are listed in the
Message dialog box. The dialog box automatically opens whenever an
error is recorded and the current error message is highlighted. All error
messages recorded during the current run are listed.
Note: To view the full message, double-click the vertical line in Description
heading or manually resize the column.

The Message dialog box has four buttons: Up/Down arrows for scrolling
to previous/next messages; Reset to reset the machine after solving the
problem that caused the error message (see Reset Machine); Help ? to
launch the application online help system.
Reset Machine
Click this button when there is a need to reset the machine. For example,
a problem that caused the machine to stop has been solved. The system
prompts you to confirm the reset. The machine then resets to Ready,
Off-line or Working status, depending on the status prior to the reset.
Note: Reset machine on the Routine Functions menu is the same as the
Reset button in the Message dialog box.
Operation Toolbar 17

Sub-menu option Description

On-line
When the Status indicator is Off-line, you cannot expose plates.
To expose plates, click On Line and wait until the machine resets to
Ready.

Shut Down
Use this option for normal machine shutdown. See Turning the
Platesetter On and Off on page 8.

Utilities Menu
Click the Utilities button to open the Utilities menu. The menu options are
described below.

Sub-menu option Description

Expose Params
The Expose Info window lists expose-related machine parameters. You
may open this window anytime before or during exposure.
Log Files
Four windows open: Machine task list, two Log message windows (for
service usage) and Expose queue list (data sent from the workstation).
Machine Info
PC Controller software version

Hardware
Lists the machine hardware parts

Setup Tables
The Plates Setup tables list the Intensity and Speed values for each plate.
You can change the values. For example, in case of under exposure, you
can increase intensity or speed for the resolution value in the expose.
18 Chapter 2 – PC Controller User Interface

Sub-menu option Description

Diagnostics
Currently not supported.

Remote Support
When you click the Remote Support button, the following appears:

Confirmation will allow the service engineer to work by remote with the
user.
Users
Defines the type of user (some application settings and preferences are
available only for service and R&D). Click Users to open the Define User
dialog box, and choose user type – user, service or R&D. Then enter
your password and click OK.
Operation Toolbar 19

Settings Menu
Click the Setting button to open the Settings sub-menu. The sub-menu
options are described below.

Sub-menu option Description

Media Definitions
Media definitions is used to define the type of plates you will be using.
(the plate must be defined before it is loaded). This option is also used to
edit the parameters of existing plates or to delete plates you will no
longer use. For details see Media Definition on page 24.
Preferences
Preferences is used to define various settings. In the Preferences dialog
box, you can set the following:
Units – choose cm or inch to set units of measurement for all
measurements, such as plate dimensions and thickness.
Language – only English is implemented.

Stop button
The Stop button on Operation toolbar is used in case of an emergency
stop. The drum and all the machine operations are immediately stopped,
and the plate remains in its current position.
20 Chapter 2 – PC Controller User Interface

Online Machine View

The Online machine view shows the platesetter during operation; it
enables you to see a simulation of machine operation. The main features
are described below.

Operational stage
When the machine is in Working status, you can identify the current
operational stage. You can see the plate loading onto the drum and the
rotating drum. The remaining process time is indicated on the Progress
indicator.

Interlock indication
When a door is open or a panel is removed, a safety interlock is activated.
The Status indicator shows Service (purple) and the Interlock indicator
appears below it with the name of the activated safety interlock. For
example, a door is open, a panel is removed or a laser interlock is activated.
For details on safety interlocks see Lotem 400 Family Safety Precautions for User,
653-00275A.

Figure 8: Main screen with Service status, interlock indicator and open doors
Online Machine View 21

Attention
When the machine status is Attention, the Online machine view may give
some indication as to the cause of the problem. For example, if the plate is
jammed inside the machine.

Perform interactive operations

You can open the front or rear door by clicking on the relevant door on the
Online machine view. (This is the same as using Open Front door and
Open Rear door on the Routine Functions menu.)
Note: When you move the cursor on the door it becomes green. See figure
below.

Figure 9: Main screen with front door green when the cursor moves on it
Plate Handling
Media Definition ...............................................................................24

Loading Plates...................................................................................26

Plate Geometry .................................................................................30

24 Chapter 3 – Plate Handling

Media Definition
You must define the type of plates you will use before loading them into the
platesetter. This option is also used to edit the parameters of existing plates
or delete plates you will no longer use.
Click Media Definitions in the Settings menu to open the Media
Definition window. Defined plate types are listed under Media list.

Note: The plate names in the window are only examples. The platesetter
supports plates of various specifications and various vendors, and Creo does not
promote specific companies’ plates.

Define new media:

1. Click New.
2. In the Name box, assign the media name. Recommended media name
includes the manufacturer name.
3. From the Manufacturer list box, select the manufacturer’s name.
Media Definition 25

4. From the Type box, select Positive or Negative. This parameter is

important for the Exposure type. For example, for a positive plate
(that is, negative working plate), choose Positive and perform a
negative exposure.
5. In the Height box, type the height in millimeters. Maximum media
height is 622 mm.
6. In the Width box, type the width in millimeters. Maximum width is
750 mm.
7. In the Thickness box, type the media thickness as listed on the plate
packaging. You must verify the media thickness with a micrometer.It
should range: 0.15 – 0.3 mm.
8. The Focus Value is automatically updated according to the media
thickness you entered in step 7.
9. In the Sensitivity box, type the value supplied by the plate vendor.
This value is important for the initial adjustment of the optic system.
10. In the Res/Int Table, select the value for your media.

11. In the Res Mtr Table, select the Res Motor Table according to your
media.
12. Click Save to save the new media. The new plate name will then
appear in the Media list.

To modify the parameters of existing media:

1. From the Media List, click the media whose parameters you want to
modify. The selected media parameters appear in Media Parameters.
2. Modify the parameters as explained in Define new media: on page 24.
You can modify all media parameters, except the plate name (Name
field is grayed).
3. Click Save to save the new parameters.

To delete a media set from the Media list:

¾ From the Media List, click on the requested plate and click Delete.
Note: To change the media name, you must first Delete the media. Then click
New to configure it again.
26 Chapter 3 – Plate Handling

Loading Plates

Loading Plates via the Workstation

The Lotem 400 platesetter has a semiautomatic plate loading process.
When an expose job is initiated by the workstation the requested plate is
placed at the center of the loading tray, emulsion side down. When the
Loading plate pushbutton is pressed and the machine is ready to expose,
the plate is automatically loaded into the platesetter.
1. Define an Expose job on the workstation (see Brisque to Lotem Family
Connectivity User Guide, 399Z3R084A).
2. A message is sent from the workstation to the PC Controller
requesting that an appropriate plate be loaded in the platesetter. The
message on the application Main window specifies the plate thickness
and size.

Figure 10: Message on PC Controller sent from workstation

3. Get the requested plate.
4. Place the plate on the loading tray (emulsion side down). Note the
printed vertical scale on the tray; its numbers are plate width sizes.
Make sure to align both sides of plate with the scale markers that
correspond to plate width.
Loading Plates 27

scale in
inches
Plate on tray
scale in
mm

Loading
plate
pushbutton

Figure 11: Loading plate tray

Note: The location of the scale markers is such that the marker is visible on both
sides of the plate when a plate that corresponds to that size is placed on tray. For
example, when a plate that is 15 inches wide is placed correctly the 15 inch
marker on each side is visible.

5. Either click OK on the message (see figure 9) or press the Loading

plate pushbutton to initiate plate loading (see figure 10).
The figures on page 28 show a small and large plate on loading tray.

When the machine is ready to expose, the plate is automatically loaded

onto the drum.
6. After the plate is loaded into platesetter, you can place another plate
on the loading tray, ready for next expose job (if the plate size is
known). The new plate is automatically loaded when the machine is
Working status. If you did not place a new plate on the tray then a
28 Chapter 3 – Plate Handling

message will appear when the machine is ready. Place the plate on the
tray and press OK. A message appears after every separation
requesting you to load the next plate.

Figure 12: A small plate on loading tray

Figure 13: A large plate on loading tray

Loading Plates 29

Loading Plates Manually

To manually load plates:
1. Define the media on the PC Controller (see Media Definition on
page 24).
2. From the Utilities menu, select Hardware.
3. Double-click Loading System.
4. In the Media To Load list, choose the type of media you want to load.
5. Get the plate you want to load.
6. Place the plate on the loading tray (emulsion side down). Note the
printed vertical scale on the tray; its numbers are plate width sizes.
Make sure to align both sides of plate with the scale markers that
correspond to plate width.
7. Push the plate inwards until both edges reach the loading stopper
door inside the platesetter.
8. In the Loading System dialog box, click Load. Make sure Media on
Drum is None. The plate is loaded.

Figure 14: Loading system window

30 Chapter 3 – Plate Handling

Plate Geometry
This section describes aspects of the plate geometry and image area. These
aspects will help you plan for the plate exposure process and define correct
settings for your press and plate, and your image offset.
The figure below shows a negative working plate, where two strips of
emulsion remain – 10 mm at the head margin and 6 mm at the tail margin.

head margin
min 10 mm

max. plate size = 750 x 622

622 mm 606 mm
max image area = 750 x 606

tail margin
min 6 mm

750 mm

head margin head gripper

Figure 15: Negative working plate – various plate dimensions

Head margin – defined on the workstation, as one of the press format
parameters. It defines the distance from the plate edge until the beginning
of the layout or the exposed image. This parameter is also known as leading
edge to print.
Tail margin – defined on the workstation as one of the press format
parameters. It defines the distance from the back edge of the plate to the
edge of the file or layout.
H (height) – plate height (around the drum).

W (width) – plate width (along the drum width).

Plate Geometry 31

In a negative exposure of a positive working plate, there is always an

emulsion area on the plate that is not exposed, therefore emulsion areas
remain. The size of these areas is determined as follows:
• At the head, the area is equal to the width of the plate and at a height of
up to 10 mm.
• At the tail, the area is equal to the width of the plate and at a height of
up to 6 mm.
The image alignment is determined by the Alignment, as defined in the
Plate Expose window on the workstation. For details, see the Brisque to
Lotem Family Connectivity User Guide, 399Z3R084.
User Troubleshooting
Generic Troubleshooting Questions ...................................................34

Startup Problems...............................................................................35

Calling Response Center For Support ................................................36

Plate Loading Failure .........................................................................37

Plate Unloading Problems..................................................................49

Exposure Failure Problem ..................................................................51

Communication Problems with TSP Board .........................................52

34 Chapter 4 – User Troubleshooting

Generic Troubleshooting Questions

There are several troubleshooting steps that you should complete before
calling the Response Center. These steps can prevent extensive down-time
by enabling you to solve problems independently. You will find these steps
are fully explained in the relevant troubleshooting document. Ideally, the
customer will have completed these steps before calling the Response
Center, and also reviewed the following questions and written the answers
down. If after completing these steps you find that the problem is not
resolved, please answer the following questions before calling the Response
Center. Write down your answers and have them available during your call.

The questions are as follows:

• When was the last time the machine worked properly?
• What was done since then? For example:
ˆ Was the machine moved?
ˆ Was the machine cleaned?
ˆ Was a new batch or type of plates used?
• Was an error message displayed on screen? If yes, what did it say
(include numbers, if any).
• What is the software version?
• Does the problem happen all the time (with all plates), or just some of
the time? For example:
ˆ With a particular plate brand, type and/or size?
ˆ Only when a few plates are left in the cassette?
• Does the problem seem to be a random occurrence?
• What are the temperature and humidity levels in the plate storage
room? For example:
ˆ Do they adhere to the plate manufacture’s guidelines? If not:
• In what ways?
• Does the temperature fluctuate radically?
Startup Problems 35

Startup Problems
Following are the most common start up problems:
• PC does not boot
• Windows does not start
• Windows does not launch
• Lotem application aborts

PC Does Not Boot

1. Verify that all power circuit breakers are in the ON position.
2. Verify that both on/off buttons at the rear of the platesetter (yellow
pushbuttons) are in the out position and lit.
3. Verify that the PC monitor power is ON.

Windows Does Not Launch

Windows does not launch and the error message relates to missing or
corrupted files.
1. Continue the startup and follow the screen instructions. Wait until the
Windows startup is complete. Then perform Windows shutdown and
reboot the PC.
2. If the startup fails and the PC hangs:
• Press F1 during initial startup and choose Safe Boot.
• Run a system check/test from AccessoriesDisk/ToolScan/Disk.
3. In some cases, Scan Disk will not resolve the problem. In such cases,
you may need to reload the following files onto your hard disk: first
Windows, then drivers, and finally the Lotem application. Please
contact your service representative for details before you proceed.
36 Chapter 4 – User Troubleshooting

Windows Does Not Start

When Windows does not start and the error message relates to boot disk/
diskette:
1. Open the rear door by inserting a long screwdriver into the holes (on
both left and right sides).
2. Open the right side door and make sure that a diskette was not left
inside the diskette drive.

Calling Response Center For Support

Whenever you need to call Creo service representative for help, the
following information should be supplied. This information is important
for addressing your problem.
• In case of an error in the PC Controller application, write down the
first five (5) error messages that are listed in the Message window of the
PC Controller main window.
• In case of error in the Brisque application, write down the Brisque
error number and message.
• In case of loading/unloading failure, write down the plate location, if
known.
• Write down the Brisque Job information (Job type, number of
separations, Screen set that is used and LW/CT resolution).
Plate Loading Failure 37

Plate Loading Failure

CAUTION: When handling the plates, especially if you need to release them,
be sure to wear protective gloves as the plate edges are sharp.

The following are the most common plate loading failures:

• Plate is stuck
• Double Loading
• Drum related errors
• Punch is stuck
The following are the most common error messages:
• Error Message: Plate did not reach punch position
• Error Message: Vacuum didn't grab plate
• Error Message: Drum Fly-off
• Error Message: Illegal plate size
• Error Message: Illegal gripper width
The following sections describe the actions that you should take when the
above failures occur.

Releasing Stuck Plates

Plates may get jammed inside the platesetter during plate loading. As
explained in Loading Plates Manually on page 29, the message sent from
the workstation to the PC Controller requests you to load a plate of
specified size and thickness. If you load a plate with an incorrect height
value, the plate will get jammed and cannot be properly loaded onto the
drum. In this case, you will need to manually remove the jammed plate.
Special precautions are required when performing this procedure.
Note: Before removing a plate, remove objects or clothing that might get caught
in the revolving drum or other moving parts, such as, ties and jewelry. Fold long
sleeves and gather long hair.
Note: Before removing a plate, switch off the main drum power switch on the
Distribution box.
38 Chapter 4 – User Troubleshooting

Note: The plate edges are sharp so the plate should not be handled with bare
hands. Wear gloves before attempting to release the plate.

Note: It is recommended to release the entire plate as one piece; do not

attempt to cut the plate.
Note: Released plates must be disposed; you may not re-use the plate.

Note: Plate remnants left in the platesetter may cause mechanical and laser
radiation hazards!

When plate loading fails because of incorrect plate size, the Status
indicator is Attention and the message window opens with the message
“Illegal plate size”.

To manually release the stuck plate:

1. You first need to open the upper door from the main window: to
interactively open the door, click on the rear door on the Machine
online view. Alternatively, click Open Rear Door from Routine
Functions menu.

2. When the rear door is open, stand at the rear side of the platesetter
and rotate the drum forward, towards the front of the platesetter.
3. Rotate the drum until you can see the detached edge of the plate, that
is, the edge that is not held by the tail grippers.
4. Hold the detached edge of plate and gently pull it towards you until
you can see the other edge of the plate, that is, the edge that is held by
the head grippers.
5. To release the plate from the head grippers: hold both sides of plate
(left and right) and pull the plate abruptly towards you.
Plate Loading Failure 39

6. Verify that the tail gripper did not move. If it did, then move it to the
Preload position (0). To do this,
a. Drag the tail gripper to the preload position (as shown in the
picture below).

b. In the Hardware dialog box, open the Loading system directory.

40 Chapter 4 – User Troubleshooting

c. Double-click Loading system.

d. In the Loading System dialog box, click Restart Plate State.

e. Click Drum Init.
f. Click Pre-load (in the same dialog box) to move the tail gripper to
the correct position according to the defined plate size.
The status indicator shows Ready (blue).
7. Close the rear door.
8. Close the loading system and hardware windows.
9. Click the Reset button in the message window, and then Reset in the
Confirm message that appears.
Machine status is now Ready and you can proceed to loading the correct
plate size.
Plate Loading Failure 41

Double Loading
Tip: Open the front door and look into the loading area in order to find out
whether double loading has occurred.

1. If the plates are in the cassette to punch area:

• Gently try to push them back into the cassette.
• If this is not possible, open the upper cover, remove the plates and
place paper in between them and then place the plates back into
the cassette.
• In the Hardware window, select Loading System/Loading System
to open the Loading System window.
• In the window, click Restart Plate State.
2. If plates are stuck halfway on the drum:
• Open the rear door.
• Then using your hands, slowly rotate the drum away from you
(towards the cassette) until you can see the plate tail edge. (A
metallic noise might be heard, which is caused by the edge being
dragged on the roller system.)
42 Chapter 4 – User Troubleshooting

3. If the plates are held by a tail gripper(s):

Figure 16: Tail gripper

• Release the gripper(s) from the plate.
• Hold the edges of both plates and pull the plates towards you until
the head gripper is visible.
• Then, press on one or two head grippers while pulling the plates
abruptly.
• Completely remove the plates from the drum.
• In the Hardware window, select Loading System/Loading System
to open the Loading System window.
• In the window, click Restart Plate State.
• Move the gripper to Preload position (see Plate Geometry on
page 30). Open the loading system and define a plate and press
pre-load.
4. Occasionally, a batch of plates may be problematic and a source for
excessive static electricity. This may cause plate-loading problems.
Tip: To minimize the probability of double loading, make sure the room
temperature is maintained between 21 to 25 degrees, and humidity is
approximately 55%.
Plate Loading Failure 43

Punch is Stuck
If the punch gets stuck while punching a plate, try the following:

Figure 17: Punch system

1. Remove the plate. If you cannot remove it, the punch pin may still be
in its low position in the plate.
44 Chapter 4 – User Troubleshooting

2. If this is the case, you need to release the punch:

ˆ Make sure the doors are closed.
ˆ In the Hardware window, select Punch System/Punch Motor/Punch
Motor xx (where xx is the punch number) and Punch System/
Detector/Punch Motor #Home Pos.Det.

ˆ The punch numbers proceed from left to right.

ˆ If you are not sure which punch needs to be released, open the front
door and remove the plate and close the door. Then activate the
punches one by one by clicking Start, to see which is the
problematic punch. If the Home Position does not change to ON,
then that is the problematic punch.
ˆ If the plate is stuck and you cannot remove it, then activate the
punches one by one by clicking Start, to see which is the
problematic punch. If the Home Position does not change to ON,
then that is the problematic punch.
If you discover a problematic punch, contact your service representative.

Drum Related Errors

Plate loading fails with drum related error Drum did not reach
position or Load Gripper is protected by Load Gripper
Protector. There may be several causes to this error message. Check the
following possibilities:
1. Verify that all covers and panels are properly closed. Make sure that no
interlock is active (that is, an interlock indicator does not appear on
the main application window, and the machine status is not Service).
2. Verify that the air compressor supply to the platesetter is adequate
(minimum setting of the air compressor should be 6 Bar).
3. From the Hardware window, select Loading System/Loading System.
In the Loading System dialog box, click Drum Init.
Plate Loading Failure 45

Error Message: Plate Did Not Reach Punch Position

Plate loading fails with error message: Plate did not reach punch
position.

1. Verify that the plates are properly centered in the cassette (both side
brackets touch the plate sides) and the rear bracket is approximately
1 mm from plate edge.
2. Check if the plate edge is bent, cut or coated with glue. This may cause
the short pins to fail a plate reading when the pins are supposed to
touch the plate (these are the centering system pins and/or the pins
near the punch blocks). Try rotating the plate 180 degrees. This may
help to verify if the plate edge is the cause of the problem.
3. Look through the cassette entrance towards the punch block units.
4. If you can see a punch pin in the middle of the punch slot, this means
that a plate may get stuck on its way to the punch. In this case, contact
your service representative.

punch slot

Figure 18: Punch

46 Chapter 4 – User Troubleshooting

Error Message: Vacuum Did Not Grab Plate

Plate loading fails with error message Vacuum did not grab plate.
Open the front door and check the plate location. The cause and solution
to this problem depends on plate location:
1. Verify that the air compressor supply to the platesetter is adequate
(minimum setting of the air compressor should be 6 Bar).
2. Open the cassette door. If you can see the plate inside the cassette,
verify that the plate edge is not under the two side brackets. In this
case, the plate cannot be loaded. Try to reposition the plate in the
cassette or add more plates into the cassette.

Figure 19: Centering system

3. Verify that the loading bar is horizontal to the plate (see below). Push
the bar toward the drum until it touches the two vertical metal
brackets. The loading bar should be parallel to the brackets on both
axes. If it is not parallel, contact your service representative.
Plate Loading Failure 47

Figure 20: XY Bar

4. If the plate is partially out of the cassette, check that all the Vacuum
suction cups on the XY bar are intact, complete and are not torn. If
there is a problem with the suction cups, contact your service
representative.
5. If the plate is halfway onto the punch blocks, examine the front edge
of the plate. If there are bends or dents in the plate, these may be as a
result of the plate hitting one of the punch blocks as it is loaded from
the cassette. Remove the plate and rotate it in the cassette.

Error Message: Drum Fly-off

1. Open the rear door, and manually remove the plate.
2. Move all tail grippers to the end of their slots (near the head grippers).
Make sure that the tail grippers are not moved beyond the head
gripper holes.
3. Verify that the load/unload rollers are in their proper position (they
did not separate from the springs).
4. Close the doors.
5. From the Hardware window, select Loading System/Loading System,
and click the following: Restart Plate State, Drum and New Plate.
48 Chapter 4 – User Troubleshooting

6. Resend the job from the Brisque.

Error Message: Illegal Plate Size

There may be several causes to this error message. Do the following:
• Measure the plate in the cassette.
• Verify that the plate size defined in the Off-line/Current Cassette dialog
box is the plate size that was actually loaded into the cassette. Plate size
should be within +/-1 mm of the dimensions defined in the Media
Definition dialog box.
• Clean the centering pins.
• Check the plate edges where the centering pins touch, see if there are
bumps, dents, dirt, glue etc... - this could prevent any electrical contact
from occurring.

Error Message: Illegal Gripper Width

There may be several causes to this error message. Check the following
possibilities:
1. Make sure no paper accompanied the plate to the centering system.
2. Open the front door and manually remove the plate from the drum.
For instructions, see Releasing Stuck Plates on page 37.
3. Move all tail grippers to the end of their slots (near the head gripper).
Make sure not to move them beyond the head gripper holes.
4. Close the front door.
5. From the Hardware window, select Loading System/Loading System.
6. In the Loading System window that is displayed, click New Plate.
7. Clean the two red LED sensors located on both sides of the drum
chassis using a dry cloth (see below).
Plate Unloading Problems 49

Figure 21: Side to side detector

Plate Unloading Problems

Plate unloading problems may be caused by one of the following:
• Plate does not unload from the platesetter
• Unload failure after plate restart

Plate Does Not Unload

1. Make sure that the previous plate entered the processor correctly.
2. If it did not, this plate may be blocking the conveyor sensor. Verify
that the processor is in Ready state, and clear any error message on the
processor panel.
3. If there is still a problem, contact the processor technician.
4. Move the previous plate into the processor. Then, from the Routine
Functions menu, click Unload Plate to manually unload the current
plate.
5. Check that there are no error messages relating to Vibration or Fly
Off. If there are such messages, please contact your service
representative.
50 Chapter 4 – User Troubleshooting

6. Try to manually unload the plate. Then load and unload a different
plate size. If this goes smoothly then there may be a specific problem
with the original plate size.

Figure 22: Unloading system

7. Load the plate into the processor. Then examine the plate to see if it
was partially exposed, or not exposed at all. If it was partially exposed,
this can indicate a problem with the exposure sequence and not a
plate-unloading problem.
Exposure Failure Problem 51

Unload Failure After Plate Restart

If you have a problem performing Restart Plate State while there is a plate
on the drum, then you will not be able to expose the plate or unload it,
because Restart Plate State resets the plate status to No plate on drum. To
resolve this problem, click Force Plate On Drum to force the system to
acknowledge the plate on the drum. Then, you can either expose the plate
or unload it.
Important: Never use Force Plate On Drum before performing a visual
check that there is actually a plate on the drum.

Exposure Failure Problem

Exposure Does Not Start

Exposure does not start at all and the error messages relates to the Host.
There may be several causes to this error message.
1. Verify the machine is ON and in Ready mode.
Note: Make sure there is no error message on the PC Controller.

2. On Brisque, go to Devices > Platesetter; select Lotem > Lotem 400.

3. Click the Reconfigure button.
4. In the Queue Manager, a red blinking icon appears on the upper part
of the dialog box indicating an error. From the Tools menu, select
Operate Control > Plate Expose > Lotem 400.
5. Click OK.
If the blinking icon disappears, then send another expose job. If not, in
the In Queue area, select the problematic error message. Double-click
it to receive an explanation of the problem.
52 Chapter 4 – User Troubleshooting

Communication Problems with TSP Board

1. Verify that the Data cable is securely connected to the workstation.
2. Check that the Network or the Point-to-Point cable between the
platesetter and the workstation is properly connected.
3. Check if you can ping the platesetter from the workstation:
• Open the terminal window on the workstation
• On the PC, open Settings/Control Panel/Network/TCPIPP/
Properties and type ping 192.9.200.2.

To stop the ping sequence type: CTRL+C.

Index
A Interlock indicator, 14 N
Active interlock name, 20 Negative plate, 25
Air pressure unit
J Negative working plate, example, 30
gauge, 8 Jammed plate
Attention status, 14, 21 precautions, 37 O
Automatic plate loading, 27 releasing, 37
Off-line status, 14, 17
On/Off pushbuttons, 4
B L Online help, 16
Brisque, 26 Language, 19 Online machine view, 20
Brisque Impose, 2 Leading edge to print, 30 Open front door
Loading plate on tray, 26, 29 interactively, 21
C Loading plate pushbutton, 26 Open rear door
Loading Plates interactively, 21
Conveyor, 6
manually, 29 Operation menu, 15
Customer site configuration, 5
via workstation, 26
Loading tray, 3, 26 P
D markers, 26, 29
PC Controller
Data & communication flow, 7 Log Files, 17
user interface, 13
Define user dialog box, 18 Log message window, 17
PC Controller monitor, 6, 12
Defining new plates, 24 Lotem 400
Plate automatic loading, 27
Deleting plates, 25 Front End, 2
Plate exit, 4
front view, 3
Plate Expose on Brisque, 31
E plate size, 2
Plate geometry, 30
power up, 8
Emergency stop, 19 Plate height, 30
product overview, 2
Emulsion area, 31 Plate stacker, 6
rear view, 4
Error messages, 16 Plate width, 30
shutdown, 9
Expose Info window, 17 Plates
Lotem 400 with MCU, 2
Expose queue list, 17 defining, 24
Exposed image area, 30 deleting, 25
M existing names, 24
F Machine parameters, 17 loading, 37
Machine reset, 16 manufacturer, 24
Front door, 3 Machine simulation, 20 placing on loading tray, 26, 29
Machine status, 14 positive/negative, 25
H Machine task list, 17 release jammed plate, 37
Head grippers, 38 Main circuit breaker, 4 sensitivity, 25
Head margin, 30 Main window, 13 thickness, 25
See also Margins active (green) door, 21 unloading, 49
Manual drum rotatation, 38 Platesetter
I Manual plate unloading, 16 online view, 20
Manually loading plats, 29 shutdown, 9
Incorrect plate size, 38 Message dialog box, 16 Positive plate, 25
Interactive operations, 21 Messages, 16 Preferences, 19
Interlock indication, 20 Pre-heat oven, 6
54 Lotem 400 Family User Guide

Press Formats
on PC controller, 30
Problems, 49
Process time indication, 20
Processor, 6
Progress indicator, 20

R
Ready status, 14
Rear door, 4
Res. Int. Table, 25
Reset button, 40
Reset machine, 16
Right side door, 3
Routine Functions, 15

S
Safety interlocks, 20
Save Plate, 25
Scale markers, plate, 26, 29
Sensitivity, 25
Service mode, 15
Service status, 14, 20
Setting, 19
Start up status, 14
Status indicator, 14
Stop button, 19

T
Tail grippers, 38
Tail margin, 30
See also Margins

U
Units of measurement, 19
User interface
features, 13
main window, 13
User types, 18
Utilities, 17

W
Working status, 14