HEIDELBERG Suprasetter 145 User manual

Suprasetter 145/162/190
User’s Guide
02/2019
Order No. PG.999.0005

ABC
Copyright © 2019 Heidelberger
Druckmaschinen AG.
No part of this book may be reprodu-
ced without prior written permis-
sion.
Heidelberger Druckmaschinen AG
Dr.-Hell-Straße
24107 Kiel
Germany
Phone [phone]
Fax [phone]
www.heidelberg.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heidelberg and the Heidelberg logo
are registered trademarks of Heidel-
berger Druckmaschinen AG.
Suprasetter is a trademark of Heidel-
berger Druckmaschinen AG.
Other company names, product
names and trademarks not expressly
mentioned in this manual are trade-
marks or registered trademarks of
the corresponding manufacturers
and fall within the regulations
regarding the protection of trade-
marks.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important notice:
We are dedicated to improving and
enhancing our products. Conse-
quently, the information in this
manual is subject to change without
notice.
Heidelberger Druckmaschinen AG
assumes no responsibility for infor-
mation and description as far as
third-party products are concerned.
The information contained in this
manual about performance and
speed as well as technical data con-
cerning application of our products
is not legally binding as it does not
constitute a written contract of fea-
tures.
If any problems occur with the prod-
uct described in this manual, please
contact the agency which is respon-
sible for you.
Translation of Original operating
manual
Order No. PG.999.0005
02/2019
Printed in Germany.
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Imprint/Company Address

Table of Contents
Suprasetter 145/162/190 – User’s Guide 3
Tab le o f Con te nt s
Table of Contents
3
Before you start ...
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Device Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Avoid Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Qualification of the Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Switch with Emergency Cutoff Function . . . . . . . . . . . . . . 11
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
On/Off button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check of the safety loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Automatic check of the safety loop . . . . . . . . . . . . . . . . . . . . . . 14
Manual check of the safety loop . . . . . . . . . . . . . . . . . . . . . . . . 15
ESD Protective Measures for Prepress Systems and Operators . . . 16
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Practical Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Standards/Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disposal of the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . . . 18
Converting the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . . . . 18
About This Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
What You Should Already Know . . . . . . . . . . . . . . . . . . . . . . . . . 19
Further Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Symbols and Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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4Version2019
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Heidelberg online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Introduction
Description of the Unit and its Functions . . . . . . . . . . . . . . . . . . . . 23
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
On/Off button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Keeping Access Routes Clear . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Notes on the Use of Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Notes on Installation
Notes on Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transport of the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . 29
Installing the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic Cutouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Software Installation (Container Version) . . . . . . . . . . . . . . . . . . 30
Saving a Backup of the Recorder Configuration . . . . . . . . . . . . . . 31
Selecting the User Interface Language . . . . . . . . . . . . . . . . . . . . 31
Operation
Power-on and Power-off Rules for Recorders with a Linux
Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Power-on order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Shutdown order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Switching on the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Manual Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Automatic Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Switching Off the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Table of Contents
Suprasetter 145/162/190 – User’s Guide 5
Shutdown using the User Interface on the Workstation . . . . . . . 37
Shutdown with the On/Off Button on the Device . . . . . . . . . . . . 37
Quick Shutdown with the On/Off button on the Suprasetter. . . . 38
Material Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Material storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Loading Plates on the Manual Device and on the Semi-automatic
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unloading the Plates on a Manual Device . . . . . . . . . . . . . . . . . . . 45
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Loading Plates on a Fully Automated Device . . . . . . . . . . . . . . . . . 46
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Empty waste box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fixing Jamming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Switching on an Automatic Cutout . . . . . . . . . . . . . . . . . . . . . . 56
Service and Maintenance
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Qualification of the Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Maintenance by the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cleaning the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cleaning the Cleaning Roller on a Manual Device and on a
Semi-automatic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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6Version2019
Cleaning the Cleaning Roller on a Fully Automated Device with a
Cross Conveyor or OLP Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removing Punch Waste on a Manual Device and on a
Semi-automatic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Removing Punch Waste on a Fully Automated Device with a
Cross Conveyor or OLP Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Changing the Filter Kit in the Suction Device . . . . . . . . . . . . . . . 71
Technical Data
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Protection and Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . 78
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . 80
Interference Emission (Stray Radiation and Interference Voltage) 80
Interference immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . 81
Approvals and Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CE-Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Labels on the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . . 83
Disposal
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Disposal of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Disposal of the Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Harmful Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Table of Contents
Suprasetter 145/162/190 – User’s Guide 7
Disposal of the Loader/Unloader . . . . . . . . . . . . . . . . . . . . . . . . 120
Harmful Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Disposal of the Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Harmful Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Disposal of the Tray Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Harmful Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Disposal of the Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Before you start ...
Suprasetter 145/162/190 – User’s Guide 9
Before you start ...
Safety Notes
The Suprasetter complies with the safety regulations of the standards and
specifications listed in the "Technical Data" chapter.
Device Names
Correct Use
The Suprasetter is a laser imagesetter for imaging offset printing plates and
may only be used for this purpose as described in the customer documenta-
tion.
All other use that does not comply with the correct use is prohibited.
Avoid Misuse
Do not place any objects or liquids on the Suprasetter.
Ventilation outlets must be kept clear at all times.
Do not use the Suprasetter as a seat.
Sales designation Type designation
Suprasetter 145/162/190 PG.010.000B
Separator PG.050.000B
Tray loader PG.090.000B
Cassette magazine PG.030.000B
I/O table PG.021.000B

Before you start ...
10 Version 2019
Qualification of the Users
After installation, users will be instructed in the operation and service and
maintenance of the Suprasetter by Heidelberg service personnel. Further
instruction, for example, for new staff employed subsequently, must be
ensured by the operator of the Suprasetter.
General
The Suprasetter may be installed only by authorized service personnel. The
ambient conditions must be observed.
For the operating company of a print shop, it is important that the exposure
limits regarding the breathable air in the work area, where the Suprasetter 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 values. In
accordance with the state of the art, this can be achieved with an 8 to 10 air
change rate per hour. If this is not the case at the installation site, the operat-
ing company should install an additional exhaust system.
Warning: Unauthorized opening of any parts of the casing not specifi-
cally referred to in the operating manual and inexpert repairs can lead
to considerable danger for the user.
Servicing may only be performed by authorized personnel trained for
this purpose. The relevant accident prevention regulations must be
observed at all times.
Non-observance of accident prevention regulations can lead to the loss
of accident insurance cover.
Warning: Plate edges can be sharp. You can injure your hands if you do
not wear protective gloves.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 11
Warning: The following loads should not be exceeded: women 15 kg,
men 25 kg.
Warning: The key-operated switch that can be seen after the top right
side panel is opened may be operated only by service personnel and not
by the operator.
The key-operated switch bypasses the safety loop.
The following risks can occur:
- Hazard of being crushed by moving parts.
- Injury from electric shock.
Warning: If cleaning the Suprasetter involves the use of liquids, discon-
nect it from the power supply beforehand. Do this by pulling out the
power connector on the service tap or by switching it off with the power
switch.
Warning: You run the risk of injuring your fingers on the sharp edges of
the printing plates if your fingers are between the insertion/ejection
table and the cross conveyor of the Suprasetter. The protective cover is
used to avoid this.
Warning: Wear disposable gloves and light dust mask We recom-
mend that you wear the disposable gloves and light dust mask included
in the kit when you are changing the filters. After you remove the filters,
clean the casing with a vacuum cleaner. Place the used filters, dispos-
able gloves, dust mask and vacuum cleaner bag in a plastic bag, tie the
bag up and dispose of it as general commercial waste. If you are not
sure about disposal procedures, contact your local waste disposal com-
pany for details.
Power Switch with Emergency Cutoff Function
The Suprasetter is fully cut off from the power supply by the power switch (red
rotary switch).

Before you start ...
12 Version 2019
The power switch (red rotary switch) separates the Suprasetter's four poles
from the power supply. In an emergency, this power switch is used as an emer-
gency stop switch for the Suprasetter.
Emergency Stop Switch
All mechanical motions in the device are stopped and the invisible laser beam
is switched off when the emergency stop switches (fully automated device: 8
units, semi-automated device: 4 units) are used.
Use these switches in cases of emergency only. They are located behind the
panels of the device. They are designed for an emergency during servicing.
On/Off button
The Suprasetter is only de-energized by the On/Off button.
The CEE or Nema outlets of the service line must be easily accessible at all
times.
To fully separate the Suprasetter from mains, e.g. in case of danger, the device
must be de-energized by actuating the power switch or unplugging the CEE or
Nema plug if applicable.
When connecting or disconnecting the power cable, make sure that your
hands are not wet and only hold the cable at the connector, if the cable has
one. A damaged power cable can cause leakage currents and electric shocks.
Protect the power cable from being damaged. Never place any heavy objects
upon it and do not allow it to get jammed.
Laser Safety
The laser imagesetter is a Class 1 laser product.
This means that the invisible laser radiation produced in the Suprasetter is
shielded by means of protective covers.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 13
If used as directed, the user is never exposed to danger from the laser beam.
The laser systems used in the Suprasetter are Class 4 products (> 500 mW).
Companies servicing the equipment in Germany must appoint a laser protec-
tion officer in compliance with the Accident Prevention Regulations (BGV B2) of
the Professional Trade Association.
Servicing may only be carried out by Heidelberg personnel who have
been trained by appropriate laser protection officers for this purpose.
Service and Maintenance
Servicing may be done solely by persons who are authorized by Heidelberg to
do so.
The relevant accident prevention regulations must be observed at all times.
Warning: Never remove covers or any other parts of the casing except
for the work described in the "Service and Maintenance" and "Trouble-
shooting" chapters. Keep exactly to the procedures laid down when
doing this.
If you do not, the invisible laser beam may cause injuries to eyes and
skin and/or you may suffer a fatal electric shock.
Warning: You may be exposed to dangerous radiation by the invisible
laser beams if you use operating or adjustment equipment other than
those mentioned in this document or if you follow other working proce-
dures.
When carrying out work as described in the customer documentation,
the user must always adhere to the operating process stipulated. Pro-
tection from invisible laser radiation is ensured by covers and safety
loops.
The use of laser protection glasses is not intended as correct operation
eliminates the need for these.

Before you start ...
14 Version 2019
Safety Loop
For your safety, the Suprasetter is equipped with a safety loop. If the safety
loop is interrupted, e.g. by removing the insertion table, all mechanical
motions are stopped and the invisible laser beam is switched off in the expo-
sure head.
Warning: The safety loop must never be bridged as otherwise you are
in danger of being injured by the invisible laser beam, of being crushed
by moving parts or being fatally injured by an electric shock.
Check of the safety loop
For the safety of the users, EN ISO 13849-1 requires that the safety function of
the Suprasetters is checked at regular intervals.
Automatic check of the safety loop
This regular check is triggered automatically after the following criteria:
• When switching on the Suprasetters
• When running certain error corrections
• When the machine is running after a period of 24 hours before the start
of a new plate sequence and a brief waiting period.
During the startup, a window displays on the CTP User Interface, pointing out
the check of the safety loop.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 15
Note: During the check of the safety loop, it is not possible to image
plates.
The window closes automatically as soon as the check is finished (this can take
some minutes).
Manual check of the safety loop
The user can run an early check of the safety loop at any time before the 24-
hour time limit expires (see "Timeframe", page 16) if, for example, a suitable
moment in production allows this.
Start check of safety loop
Caution: During the test no imaging jobs may be processed! In other
words, no plates must be in the device and no jobs are waiting for pro-
cessing. You must stop processing beforehand.
The check of the safety loop starts after you click this button in the
user interface and confirm again.

Before you start ...
16 Version 2019
Timeframe
ESD Protective Measures for Prepress Systems and
Operators
Basics
Devices from Heidelberger Druckmaschinen AG are resistant to electrostatic
discharges (within the limits of EN 55024:2001).
In order to protect devices and users from being unnecessarily exposed to such
discharges, we have listed a few tips below that will help reduce the frequency
and intensity of the discharges.
Formation
In a prepress environment, this physical phenomenon occurs most frequently
as a result of triboelectricity. In such cases, electrostatic charges are generated
when bodies that have close contact are separated.
This displays the interval until the next regular safety loop
test.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 17
Examples:
• Walking across non-conductive (insulating) flooring (e.g. synthetic floor
covering)
• Removing the slip sheet from the plate
• Getting up off a seat
The intensity of these charges is determined basically by the following param-
eters:
• Humidity
• Roughness of the material surface
• Pressure/space when in contact
• Conductivity of the materials
Practical Tips
The following practical tips are to help reduce the number and intensity of elec-
trostatic discharges when handling the devices:
• Install the devices in rooms that have conductive floor covering.
• Resistance to ground < 1x109ohms (IEC/EN 61340-5). Synthetic carpet-
ing does not comply with this requirement in the majority of cases. Pure
concrete flooring generally has a low volume resistance. If you have non-
conductive floor covering, the use of ESD mats placed on the operator
side of the devices is recommended. These mats can be obtained from
suppliers. However, in such a case, existing charges are only slowly
reduced depending on the shoes that the personnel wear. For personal
safety, the resistance of floor to ground should not fall below 105 ohms.
• The humidity at the installation site should not fall below 45% relative
humidity. High air humidity is a decisive factor in preventing the forma-
tion of electrostatic charges. For example, a relative humidity of 10 - 20%
will produce 35,000 V when crossing a carpet. This value drops to 1,500
V with a relative air humidity of 65 - 90%.

Before you start ...
18 Version 2019
• Clothing where cotton material is >50%.
• Conductive seating.
• ESD shoes that can be obtained from suppliers and are used on conduc-
tive flooring help further to reduce charges when walking across floor
coverings.
Standards/Sources
More details on this subject can be found in the following sources:
• IEC / EN 61340-5 (Protection of electronic devices from electrostatic
phenomena - General Requirements)
• Electrostatic Discharge Association
http://www.esda.org/
• Electrostatic Society of America
http//www.electrostatics.org
Disposal of the Suprasetter 145/162/190
The disposal of the Suprasetter 145/162/190 is described in chapter Disposal.
Converting the Suprasetter 145/162/190
Any conversion work on the Suprasetter 145/162/190 may be performed only
by Heidelberg service personnel.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 19
About This Documentation
This documentation is intended as a reference work for the operator during
training courses and in operation.
Note: The documentation must be kept safely for future use right up to
the disposal of the Suprasetter.
What You Should Already Know
The user, having attended a training course, should be familiar with the Supra-
setter.
Further Documentation
You can find more information in the following documentation:
• Prinect MetaDimension - User's Guide/Workflow
• Prinect Integration Manager - User's Guide/Workflow
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Symbols and Styles
The following typographical conventions are used in this manual:
• References to other chapters and sections are blue (on the screen) and
underlined.
Example: See section "Symbols and Styles", page 20.
• Quotes are used to indicate menus, folders, functions, hardware condi-
tions, switch settings, system messages, etc.
Example: Set the switch to "off".
• Menus, functions and sub-functions are separated by ">".
Example: Select "File > Open...".
• Buttons which you should hold down simultaneously are connected with
a plus character.
Example: Press Alt+A.