Lotem 400 Family UG - Kodak

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 

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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. 

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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 noninfringement. 

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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. 

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Patents 

This product is covered by one or more of the following U.S. patents: 

RE37,376 

4,558,302 

4,743,091 

4,992,864 

5,049,901 

5,079,721 

5,103,407 

5,111,308 

5,113,249 

5,122,871 

5,124,547 

5,132,723 

5,150,225 

5,153,769 

5,155,782 

5,157,516 

5,208,818 

5,208,888 

5,247,174 

5,249,067 

5,283,140 

5,291,273 

5,323,248 

5,325,217 

5,339,176 

5,343,059 

5,355,446 

5,359,451 

5,359,458 

5,367,360 

5,384,648 

5,384,899 

5,412,491 

5,412,737 

5,420,702 

5,420,722 

5,459,505 

5,473,733 

5,481,379 

5,488,906 

5,497,252 

5,508,828 

5,509,561 

5,517,359 

5,519,852 

5,526,143 

5,532,728 

5,561,691 

5,568,595 

5,576,754 

5,579,115 

5,592,309 

5,594,556 

5,600,448 

5,608,822 

5,615,282 

5,625,766 

5,636,330 

5,649,220 

5,650,076 

5,652,804 

5,680,129 

5,691,823 

5,691,828 

5,696,393 

5,699,174 

5,699,740 

5,708,736 

5,713,287 

5,742,743 

5,764,374 

5,764,381 

5,771,794 

5,785,309 

5,813,346 

5,818,498 

5,854,883 

5,861,904 

5,861,992 

5,875,288 

5,894,342 

5,900,981 

5,934,196 

5,942,137 

5,946,426 

5,947,028 

5,958,647 

5,966,504 

5,969,872 

5,973,801 

5,986,819 

5,995,475 

5,996,499 

5,998,067 

6,003,442 

6,014,471 

6,016,752 

6,031,932 

6,043,865 

6,060,208 

6,063,528 

6,063,546 

6,072,518 

6,090,529 

6,096,461 

6,098,544 

6,107,011 

6,112,663 

6,115,056 

6,121,996 

6,130,702 

6,134,393 

6,136,509 

6,137,580 

6,147,789 

6,158,345 

6,159,659 

6,164,637 

6,180,325 

6,181,362 

6,181,439 

6,186,068 

6,189,452 

6,191,882 

6,204,874 

6,208,369 

6,214,276 

6,217,965 

6,260,482 

6,266,080 

6,266,134 

6,267,054 

6,268,948 

6,283,589 

6,295,076 

6,299,572 

6,318,266 

6,352,816 

6,353,216 

6,366,339 

6,371,026 

6,377,739 

6,387,597 

6,396,422 

6,396,618 

6,407,849 

6,414,755 

6,422,801 

6,435,091 

6,441,914 

6,450,092 

6,456,396 

6,476,931 

6,477,955 

6,509,903 

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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 

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 

vii

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


Scope of This Manual........................................................................viii

viii 


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.


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 

workstation 

PC controller 

monitor 

Conveyor 

Lotem 400 

Processor 

Figure 3: Typical configuration at customer site


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 

Data cable (TSP) 

Point to point 

Workflow 

workstation 

Data from prepress 

Network TCP/IP 

100B/T 

Figure 4: Communication & data flow between platesetter & workstation


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 

indicator 

Message 

area 

Online machine view 

Figure 7: Main window areas


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 

Routine Functions Menu 

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. 

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.



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.



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. 


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.



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.


Settings Menu 

Click the Setting button to open the Settings sub-menu. The sub-menu 

options are described below. 


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.


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: 

‣ 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.


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 

Plate on tray 

scale in 

inches 

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


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


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 

max image area = 750 x 606 

606 mm 

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: 

 

 

 

Was the machine moved? 

Was the machine cleaned? 

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: 

 

 

With a particular plate brand, type and/or size? 

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: 

Do they adhere to the plate manufacture’s guidelines? If not: 

• In what ways? 

• Does the temperature fluctuate radically?

Startup Problems 35 

Startup Problems 

PC Does Not Boot 

Following are the most common start up problems: 

• PC does not boot 

• Windows does not start 

• Windows does not launch 

• Lotem application aborts 

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.


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 

Releasing Stuck Plates 

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. 

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.


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.


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.


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.


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.)


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%.


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.


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

 

 

 

 

Make sure the doors are closed. 

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. 

The punch numbers proceed from left to right. 

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. 

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.


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


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.


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.


6. Resend the job from the Brisque. 

Error Message: Illegal Plate Size 

Error Message: Illegal Gripper Width 

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. 

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 Does Not Unload 

Plate unloading problems may be caused by one of the following: 

• Plate does not unload from the platesetter 

• Unload failure after plate restart 

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.


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.


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 

Active interlock name, 20 

Air pressure unit 

gauge, 8 

Attention status, 14, 21 

Automatic plate loading, 27 

B 

Brisque, 26 

Brisque Impose, 2 

C 

Conveyor, 6 

Customer site configuration, 5 

D 

Data & communication flow, 7 

Define user dialog box, 18 

Defining new plates, 24 

Deleting plates, 25 

E 

Emergency stop, 19 

Emulsion area, 31 

Error messages, 16 

Expose Info window, 17 

Expose queue list, 17 

Exposed image area, 30 

F 

Front door, 3 

H 

Head grippers, 38 

Head margin, 30 

See also Margins 

I 

Incorrect plate size, 38 

Interactive operations, 21 

Interlock indication, 20 

Interlock indicator, 14 

J 

Jammed plate 

precautions, 37 

releasing, 37 

L 

Language, 19 

Leading edge to print, 30 

Loading plate on tray, 26, 29 

Loading plate pushbutton, 26 

Loading Plates 

manually, 29 

via workstation, 26 

Loading tray, 3, 26 

markers, 26, 29 

Log Files, 17 

Log message window, 17 


Front End, 2 

front view, 3 

plate size, 2 

power up, 8 

product overview, 2 

rear view, 4 

shutdown, 9 

Lotem 400 with MCU, 2 

M 

Machine parameters, 17 

Machine reset, 16 

Machine simulation, 20 

Machine status, 14 

Machine task list, 17 

Main circuit breaker, 4 

Main window, 13 

active (green) door, 21 

Manual drum rotatation, 38 

Manual plate unloading, 16 

Manually loading plats, 29 

Message dialog box, 16 

Messages, 16 

N 

Negative plate, 25 

Negative working plate, example, 30 

O 

Off-line status, 14, 17 

On/Off pushbuttons, 4 

Online help, 16 

Online machine view, 20 

Open front door 

interactively, 21 

Open rear door 

interactively, 21 

Operation menu, 15 

P 

PC Controller 

user interface, 13 

PC Controller monitor, 6, 12 

Plate automatic loading, 27 

Plate exit, 4 

Plate Expose on Brisque, 31 

Plate geometry, 30 

Plate height, 30 

Plate stacker, 6 

Plate width, 30 

Plates 

defining, 24 

deleting, 25 

existing names, 24 

loading, 37 

manufacturer, 24 

placing on loading tray, 26, 29 

positive/negative, 25 

release jammed plate, 37 

sensitivity, 25 

thickness, 25 

unloading, 49 

Platesetter 

online view, 20 

shutdown, 9 

Positive plate, 25 

Preferences, 19 

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

Lotem 400 Family UG - Kodak

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