HEIDELBERG Suprasetter A52 Installation Manual
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HEIDELBERG Suprasetter A52 Installation Manual

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Suprasetter A52/A75
Installation
07/2019
Order No. PJ.999.0002/03

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Summary of Contents for HEIDELBERG Suprasetter A52

  • Page 1 Suprasetter A52/A75 - Installation Suprasetter A52/A75 Suprasetter A52/A75 Installation 07/2019 Order No. PJ.999.0002/03...
  • Page 2 Conse- tion and description as far as third- contact the Heidelberg agency which quently, the information in this man- party products are concerned. is responsible for you.

  • Page 3: Table Of Contents

    Safety with Heidelberg Remote Service ........
  • Page 4 Installation Suprasetter A52/A75 ........
  • Page 5 Technical Data of Suprasetter A52/A75 ........

  • Page 7: About This Documentation

    Before you start ... About This Documentation This documentation applies to Suprasetter A52/A75. The Suprasetter A52/A75 is a laser imagesetter, with an optional Autoloader and output table to the online processor, for imaging offset printing plates. Symbols and Styles The following typographical conventions are used in this manual: •...

  • Page 8: Important Information

    Before you start ... Important Information Important information in the text is indicated by symbols at the side which are used as follows: DANGER The "DANGER" signal word indicates a hazard with a high risk which, if not avoided, will result in death or severe injury. WARNING The "WARNING"...

  • Page 9: Safety

    Safety Safety Safety with Suprasetter A52/A75 Intended Use The Suprasetter is a laser imagesetter with an optional Autoloader and output table to the online pro- cessor, for imaging offset printing plates and may only be used for this purpose as described in the operating instructions.

  • Page 10: Power Supply

    Safety For the operating company of a print shop, it is important that the exposure limits regarding breath- able air in the work area (where the platesetter is located) are adhered to. The air exchange must be arranged in such a way that the measured dust particles are regularly below the exposure limit val- ues.

  • Page 11: Additional Protective Conductor Terminal

    PE terminal (Fig. 2/1). In addition, you must make sure that the PE is routed further in the ser- vice tap with a cable cross section of at least 10 mm². Fig. 2 PE terminal Suprasetter A52/A75 – Installation...

  • Page 12: Power Switch With Emergency Stop Function

    Safety Power Switch with Emergency Stop Function The power switch triggers a bipolar cut-off of the Suprasetter from the power supply. In an emer- gency, this power switch is used as an emergency stop switch for the Suprasetter. The power switch with emergency stop function is located on the right side of the Suprasetter.

  • Page 13: Safety Loop

    The key can not be removed in the Service mode. It is therefore not possible to close the door as long as the unit is in the service mode. WARNING Risk of injury from improper operation The service switch may be operated only by the service technicians. Suprasetter A52/A75 – Installation...

  • Page 14: Laser Safety

    Companies servicing the equipment in Germany must appoint a laser protection officer in compliance with the Accident Prevention Regulations (BGV B2) of the Professional Trade Association. Note: Servicing may only be carried out by Heidelberg personnel who have been trained by appropriate laser protection officers for this purpose.

  • Page 15: Laser Standards And Regulations

    21 CFR 1040 (USA) standards. Service and Maintenance Service work may be performed solely by persons authorized by Heidelberg to do so. When perform- ing the work described in the operating instructions and service manual, the service personnel must adhere to the described work sequence under any circumstances.

  • Page 16: Standards

    Safety Standards This device complies with the safety regulations of the standards listed below. Product Safety Product Safety Act (2011) Germany 2006/95/EC Low-voltage directive Europe 2006/42/EC EC directive relating to machinery Europe 2004/108/EC EMC directive Europe EMVG Act concerning the electromagnetic compatibility of devices Germany Tab.

  • Page 17: Radio Interference Suppression

    Approvals and conformity certified Germany Declaration of Conformity Europe cETLus certified USA / Canada CDRH Accession-No. (submitted) CFR 47 Part 15, Subpart B, Class A GOST-R certified Russia 004 395 779 Australia Tab. Approvals and conformity Suprasetter A52/A75 – Installation...

  • Page 18: Cleaning

    Undiluted liquids with an ethylene glycol content of ca. 90% must be treated as hazardous waste and can be incinerated in hazardous waste facilities under consideration of local regulatory stipulations. See also the "Disposal" chapter in the Suprasetter A52/A75 - Operation manual.

  • Page 19: Overview Of Labels

    On the rear of the Suprasetter above the power switch: Fig. 6/1: Power switch symbols Fig. 7 Power switch symbols On the rear of the Suprasetter: Fig. 6/2: Note on FCC conformance Fig. 8 Note on conformance Suprasetter A52/A75 – Installation...
  • Page 20 Safety On the rear of the Suprasetter: Fig. 6/3: Laser Product Class 1 Fig. 9 Laser Product Class 1 On the outer rear of the Suprasetter and inside rear above the electronics box: Fig. 6/4 and Fig. 14/5: Type label Fig.
  • Page 21 3: Equivalent leakage current 4: High leakage current 5: Type label Fig. 14 Recorder inside rear Fig. 12/2 and Fig. 13/2: At the machine front and at left and right chassis side. Fig. 15 Beware of moving parts Suprasetter A52/A75 – Installation...
  • Page 22 Safety Fig. 14/3: At the rear on the mains terminal box Fig. 16 Equivalent leakage current, information about additional PE cable Fig. 12/1 and Fig. 13/3: At the machine front and at left and right chassis side. Fig. 17 Class 4 laser radiation Fig.
  • Page 23 (only on a fully automated machine) 0.8 MPa = 8 bar = 120 PSI Fig. 22 Air inlet (compressed air connection) On the laser module Aperture Class 4 laser Fig. 23 Laser Class 4 Suprasetter A52/A75 – Installation...
  • Page 24 Safety Fig. 13/4: On the filter unit Fig. 24 Filter replacement...

  • Page 25: Safety With Heidelberg Remote Service

    Safety Safety with Heidelberg Remote Service Heidelberg Remote Service Remote Service covers Remote Monitoring and Remote Control. Be careful when the key-operated switch is activated and Remote Control is performed. This allows dangerous movements to be remotely triggered. Safety Precautions During Remote Control...
  • Page 26 Safety Fig. 26 Warning sign copy template...

  • Page 27: General

    Control is enabled only when the customer gives his/her consent by pressing the input key at the front right of the machine. Confirmation is valid as long as the key-operated switch remains in its position. It is required again when the key-operated switch has been switched off and on again. Suprasetter A52/A75 – Installation...
  • Page 28 Safety Confirmation is always required, regardless of whether the DIAG or GUI application controls the machine locally or remotely. An automatic timeout occurs after 10 minutes to prevent infinite remote control sessions without pressing the confirmation key. The on-site monitor also indicates that the key- operated switch has been turned and the safety loop thus has been bypassed.

  • Page 29: General

    The floor (covering) must have an abrasion-proof, easy-to-clean, smooth surface, it must be antistatic and meet the following quality requirements: ≤ 500 V/cm Max. charge ≤ 30 sec Half-life period ≤ 10 Ω Leakage resistance ≤ 10 Ω Volume resistance Tab. Electrical floor properties Suprasetter A52/A75 – Installation...

  • Page 30: Machine's Arrival At The Customer's

    Fig. 1 Suprasetter with Autoloader through narrow door Protection Against Corrosion All HEIDELBERG machines are coated with VCI corrosion protection and sealed with PVC foil prior to shipment. Underneath the foil a special atmosphere forms that protects the machine against corro- sion.

  • Page 31: Provision Of A Power Cable

    If necessary, you can contact the plate manufacturers for their specifications. Observe the following items when handling printing plates: • Plate edges can be sharp - wear gloves! • Never touch the emulsion side with your bare hands. • The surface is sensitive to scratches. Suprasetter A52/A75 – Installation...

  • Page 32: Special-Purpose Tools

    Installation Preparation Special-Purpose Tools Service Pushbutton for Chiller The pushbutton lets you start the pump in the chiller during coolant filling. Fig. 2 Service pushbutton for chiller Description Service adapter X158 Part number BP.007.0052/ Usage Chiller • For chiller filling: container (2 liters), graduated cup (2 liters) and water. Coolant: 1.5 liter can, order No.

  • Page 33: Adapter For Service Terminal

    Service monitor connection Device for Laser Head Insertion Device for tightening the spring that holds the inserted laser module. Fig. 5 Laser head insertion tool with thumb wheel Description Clamp Part number BV.011.9860/01 Usage Laser module Suprasetter A52/A75 – Installation...

  • Page 34: Spirit Level

    Installation Preparation Spirit level Accuracy 0.05° Model, e.g. Bosch DNM 60 L Fig. 6 Spirit level Description Electronic spirit level Part number 00.894.1437/ Application Adjustment Hose cutter Hose cutter for rectangular cutting of hose ends up to 12 mm Ø. Fig.

  • Page 35: Unloading Aid/Ramp

    Installation Preparation Unloading aid/ramp Fig. 8 Ramp Description Unloading aid/ramp Part number BV.013.8185 Usage Installation; lifting the Suprasetter off the pallet Note: See the chapter "Tools" in the service manual for further service tools. Suprasetter A52/A75 – Installation...

  • Page 36: Pallet / Installation Instructions

    Installation Preparation Pallet / Installation Instructions...

  • Page 37: Installation Suprasetter A52/A75

    Fig. 1 Instruction on the pallet NOTICE Fork-lift truck In the installation instructions enclosed with the Suprasetter, the three exclama- tion points draw your attention to the fact that you must open the doors carefully and not too far. Suprasetter A52/A75 – Installation...
  • Page 38 Installation Remove the front covering: To do so, pull the upper part of the covering towards you (magnetic lock) and lift it out at the bottom. Fig. 2 Front covering Loosen the 3 clips in the rear covering by 1/4 turn and take off the rear panel.

  • Page 39: Installation Of The Suprasetter

    Place a spirit level on the milled part of the cast chassis and align it in horizontal direction by adjusting the rear feet of the cast chassis. Fig. 5 Spirit level, rear Suprasetter A52/A75 – Installation...
  • Page 40 Installation Open the lateral doors and place the spirit level on the cast chassis. Align in horizontal direction by adjusting the front feet of the cast chassis. Fig. 6 Spirit level, left side Pull off connector X206 (Fig. 7/2 and Fig. 8/2). Only for a semi-automatic device: Loosen the brackets on both sides of the Suprasetter (Fig.
  • Page 41 Unscrew the screws (Fig. 9/2, two each on left and right) and pull out the paper chute. Fig. 9 Screws (if Autoloader used) Only with DTL: Open cover and remove 3 screws (Fig. 10/1). Fig. 10 Cover fastening, fully automatic machine Suprasetter A52/A75 – Installation...
  • Page 42 Installation Remove 3 screws each on both sides of the cover (Fig. 11/1). Take off the cover with 2 persons. Fig. 11 Cover rail...

  • Page 43: Transport Safeguards

    Cut and remove the cable tie of the punch waste box (Fig. 12; only with the "Punch" option). Fig. 12 Punch waste containers Loosen the four screws from the bracket and remove the bracket (Fig. 13/1). Fig. 13 Transport safeguard: Swivel table right Suprasetter A52/A75 – Installation...
  • Page 44 Installation Cut open and remove the cable tie securing the transport roller (Fig. 14/1). In addition for a semi-automatic device: Cut open and remove the cable tie securing the gate. Fig. 14 Transport safeguard: Roller Note: Figure shows DTL. Cut open and remove the cable ties for NIP roller (Fig.
  • Page 45 (Fig. 18/1) and VCT bar (Fig. 18/2). Fig. 18 Transport safeguard: NIP roller and VCT bar left Loosen the four screws (Fig. 19/1) of the feed motor and remove the bracket. Fig. 19 Transport safeguard: Feed motor Suprasetter A52/A75 – Installation...
  • Page 46 Installation Loosen the lock nut (Fig. 20/1) on the drum. Fig. 20 Transport safeguard: Lock nut Undo the screw (Fig. 21/1) and the cable tie (Fig. 21/2). Fig. 21 Transport safeguard: Locking screw Only with the Exhaust option: Unscrew four screws and remove the plate secur- ing the exhaust pump (Fig.
  • Page 47 1) on the clamps of the exhaust filter. Fig. 23 Transport safeguard: Exhaust filter At front of the Suprasetter: Loosen the four screws (Fig. 24/1) and remove the bracket securing the laser carriage. Fig. 24 Transport safeguard: Laser carriage Suprasetter A52/A75 – Installation...
  • Page 48 Installation Loosen the screws of the four brackets (Fig. 25/1) and remove the brackets. Cut open the cable ties (Fig. 25/2) and remove them. Fig. 25 Transport safeguard: Load table Note: Stand-alone devices can have two cable ties. In this case, loosen and remove both cable ties.

  • Page 49: Checking Centering

    Check the clearance on both sides of the Supra- setter by pushing the chassis (supported on rubber blocks) to the front, to the rear and to both sides. The two rings must not touch the edge of the recess. Fig. 29 Centering Suprasetter A52/A75 – Installation...

  • Page 50: Additional Work With Conveyor Option

    Installation Additional Work with Conveyor Option The conveyor comes separately packed. Remove the top rear cover (Fig. 30/1) and the bezel (Fig. 30/2). Fig. 30 Conveyor retainer Screw two combination screws at the top left and right (Fig. 31/1) loosely into the conveyor. Fig.
  • Page 51 Start at the swivel area of the rotary table/the opto switch lug and secure with cable ties. The cable between connector X69 (Fig. 36/1) and cable tie (Fig. 36/2) should be 220 mm long. Plug connector X69 (Fig. 36/1) to motor M80. Fig. 36 X69 Suprasetter A52/A75 – Installation...
  • Page 52 Installation Route the adapter (Fig. 37/1) to the electronics box. Make sure for EMC reasons to route the cables as close to the sheet metal as possible. Fig. 37 Cable routing Plug connector X22 (Fig. 38/22) to the DSC board. Plug connector X16 (Fig.

  • Page 53: Compressed Air Connection

    Only with the Fully Automated or Double Table option: Route and connect the compressed air hose (Fig. 39/1; behind the right door). Fig. 39 Compressed air connection Set the pressure to 6 bar with the adjusting valve (Fig. 40/1). Fig. 40 Adjusting valve Suprasetter A52/A75 – Installation...

  • Page 54: Install Laser Module

    Installation Install Laser Module DANGER Danger! High Voltage! When the Suprasetter is switched on, parts in the device are live. The Suprasetter must be in an off-state for subsequent work. NOTICE Sensitive contacts Make sure not to touch the contacts (Fig. 41/2). NOTICE Sensitive lens Do not touch the lenses!
  • Page 55 Again, you must pull back the hose somewhat so the collet grips the hose. Align the hoses as shown in Fig. 41/1. Fig. 43 Laser module hose connection NOTICE Sensitive contacts Make sure not to touch the PCB contacts (Fig. 44/3)! Suprasetter A52/A75 – Installation...
  • Page 56 Installation Unplug connector X381 (in front of the module slot) to gain more space. Check that the PCB is not damaged. Remove the protective foil from the lens. Clean the module slot with a lint-free cloth if necessary. Make sure that the spring (Fig. 44/1) enters the hole (Fig.
  • Page 57 To pull a hose out of its holder, first push the hose slightly into the holder, then hold the ring (Fig. 47/ 2) in the direction of the arrow and pull out the hose (Fig. 47/1). Fig. 47 Hose NOTICE Do not twist the hoses (Fig. 48/2). Suprasetter A52/A75 – Installation...
  • Page 58 Installation Vigorously push the hoses (Fig. 48/2) into the cou- plings (Fig. 48/1) as far as the stop (Fig. 42). Fig. 48 Fit hoses Fit connector X381 again. NOTICE Beware of short circuit Do not tilt the laser module while it is energized.

  • Page 59: Power Connection

    Fasten the cover plate of the mains terminal box back on again with the three screws. Fasten the additional PE wire with the M5 screw and secure the cable with the clamp. Fig. 50 Additional PE connection Suprasetter A52/A75 – Installation...
  • Page 60 Installation Tighten the strain relief for the power cable (Fig. 51/1). Fig. 51 Power cable strain relief...

  • Page 61: Connection Of Suprasetter To Pc

    Fig. 52 GUI, Gigabit, LVDS and OLP cables Fasten the Gigabit or LVDS cable (and, if any, the OLP cable from X121 (Fig. 52/4)) as shown in Fig. 53/1 with two cable ties to the chassis. Fig. 53 Strain relief Suprasetter A52/A75 – Installation...

  • Page 62: Set Up The Pc

    Installation Set up the PC DANGER Danger! High Voltage! Even when the PC is switched off, parts in the PC are still live. The PC may not be connected to the power supply during installation of the cards. The Suprasetter must be switched off. Pull out the power connector of the PC and open the side panel.
  • Page 63 Installation Select the network. Fig. 55 Network Select Network Connections and select "Local Area Connection 2". Fig. 56 Network Connections Suprasetter A52/A75 – Installation...
  • Page 64 Installation Also enable "Show icon in notification area when connected". Fig. 57 LAN Connection 2 Properties Click "Properties" and specify the IP address. Fig. 58 IP address...
  • Page 65 OK. Check after the first PC start if the existing PC has correctly detected the second hard disk required for the page buffer. The volume name must be PAGEBUFF. Fig. 61 Advanced Settings Suprasetter A52/A75 – Installation...

  • Page 66: Software Installation

    Installation Software Installation Installing the Recorder Software For installation, follow the instructions in the "Linux_Install...pdf" and "Revision-History.pdf" documents on the USB stick. The required CtP recorder software is shipped on a USB stick. The USB stick is secured with a cable tie near the safety switch in the Suprasetter and must also be re-attached there after installation (Fig.

  • Page 67: Configuration Of Suprasetter

    Attach the USB stick. Cancel the setup program for the Suprasetter operating software if it should start automatically. In Windows Explorer start the "...\Diagnostic SW\Suprasetter_Diag\SETUP.EXE" file. Confirm the queries. The setup copies all the components of the diagnostic software into the specified directory and cre- ates the "Diagnose" program group. Suprasetter A52/A75 – Installation...

  • Page 68: Configure Diag

    The "Speedway Target Configuration" window, in which you must set "Main Target" to "active", appears on top of the large diagnosis window. Use the "Select" button to open "C:\Program- Files(x86)\Heidelberg\CTP\Diagnose Supraset- ter_A75\DIAG Suprasetter_A75\Diag Supraset- ter.tdb". Fig. 64 Speedway Target Configuration In the "Interface Settings"...

  • Page 69: Toggling The Language

    Make sure to wear protective gloves and goggles when handling coolant. NOTICE Water containing chlorine damages the cooling hoses. Only drinking water without any chlorine, alternatively distilled water, may be used. Suprasetter A52/A75 – Installation...
  • Page 70 Installation Description No error Flashing OFF Warning: Water below MAX mark Flashing OFF Flashing Error: Water below MIN mark Flashing Error: Water flow < 0.5l/min. Flashing Error: Fan speed < 1500 rpm. Flashing Error: Temperature < 15°C or > 35°C or controller faulty In the test mode: Water above the MIN and MAX marks In the test mode: Water above the MIN mark Tab.
  • Page 71 68/3). 4. Prepare coolant made up of 1 part Glysantin : 3 parts chlorine-free drinking water, 25% in the measuring cup (Fig. 68/1). Initial filling: ca. 1 liter Top-up filling: ca. 0.2 liters Fig. 68 Filling Suprasetter A52/A75 – Installation...
  • Page 72 Installation 5. Unscrew the two screws from above for the bracket (Fig. 68/3) to which the filler hose is fastened. 6. Plug X158 of the service pushbutton (see position 9 in Table Filling/3) to X158 on the chiller PCB (Fig. 69/1). 7.
  • Page 73 LOWER LEVEL (H2) and UPPER LEVEL (H1) have been reached when both LEDs are lit while the but- ton is being pressed. 15. Release the service button and wait for ca. 3 seconds until the liquid has stopped circulating. Suprasetter A52/A75 – Installation...
  • Page 74 Installation 16. If necessary, mix an additional small amount of coolant in the measuring cup (Fig. 68/1) and fill it into the funnel (Fig. 68/2) with the shutoff valve (Fig. 72/1) opened until the liquid level has reached the MAX mark. 17.

  • Page 75: Fully Automatic Device

    Align the paper chute with the closed front cover- ing and then secure with four screws. Fig. 73 Paper chute Thread both stay tubes into the collecting net. Hook the net (Fig. 74/1) into both rails (Fig. 74/ arrows). Fig. 74 Net Suprasetter A52/A75 – Installation...

  • Page 76: Dual Top Loader (Option)

    Installation Dual Top Loader (Option) Format setting on insertion table, bottom Set the format guides (Fig. 75 /1) according to the size required. Fig. 75 Insertion table, bottom Taller format guides for as many as 150 printing plates For operation with the insertion table only (with- out a tray), the format guides (Fig.

  • Page 77: Format Setting On Tray

    (unhook spring / reposition module / tighten spring again) if an error message about the laser module displays after initialization of the Suprasetter. NOTICE Beware of short circuit Do not tilt the laser module while the Suprasetter is switched on. Suprasetter A52/A75 – Installation...

  • Page 78: Install Web-Based Remote Service System Via Axeda

    More details are published as service information in the service point. Fig. 78 System service Access for registered Heidelberg employees and partners https://heires.heidelberg.com/start Request documents for access RemoteServiceSupport@heidelberg.com Testing Set up material Set up material using the Material Wizard (length, width, thickness).

  • Page 79: Connecting The Online Processor To The Suprasetter

    (Fig. 79/1) in the Suprasetter. Fig. 79 OLP connection X121 in the Suprasetter Connect the equipotential bonding cable from the online processor to the ground point (Fig. 80/1) in the Suprasetter. Fig. 80 OLP connection point for ground connection Suprasetter A52/A75 – Installation...
  • Page 80 Installation Note: Interface Description A PDF to be found in Sherlock in "PT000 Computer to Plate -> PL000 Suprasetter -> SRH Service Manual Suprasetter -> Maintenance and Repair -> Repair (Removal and Installation) -> Online Processor Interface" describes the interface to the online processor in detail.

  • Page 81: Technical Data

    Technical Data Technical Data Technical Data of Suprasetter A52/A75 Type Value Comment Dimensions 1550 mm x 1218 mm x 1350 mm Manual WxDxH 1550 mm x 1871 mm x 1350 mm WxDxH, semi-automatic machine 1550 mm x 2371 mm x 1350 mm...
  • Page 82 Technical Data Type Value Comment Resolution 1000 pixels/cm (2540 dpi)
  • Page 83 LEDs 72 M Machine feet 37 Microswitch S2 70 On-line Processor 77 Options 48 Pallet 34 Paper chute 73 PC connection 59 PCB 00.785.1151 70 Plate material 29 Power cable 8 Power connection 57 Power supply 8 Suprasetter A52/A75 – Installation...
  • Page 86 Fax +49 6221 92-6999 www.heidelberg.com Trademarks Heidelberg, the Heidelberg logotype, Prinect, Suprasetter and Speedmaster are registered trade- marks of Heidelberger Druckmaschinen AG in the United States and other countries. Adobe and PostScript and Acrobat are either registered trademarks or trademarks of Adobe Systems Incorporated in the United States and/or other countries.

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