HEIDELBERG Suprasetter 145 User manual

Suprasetter 145/162/190
User’s Guide
08/2019
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
08/2019
Printed in Germany.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Imprint/Company Address

Table of Contents
Suprasetter 145/162/190 – User’s Guide 3
Tab le o f Con te nt s
3
Before you start ...
About This Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What You Should Already Know . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols and Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Device Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Avoid Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Qualification of the Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Switch with Emergency Cutoff Function . . . . . . . . . . . . . . 13
Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
On/Off button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check of the safety loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Automatic check of the safety loop . . . . . . . . . . . . . . . . . . . . . . 16
Manual check of the safety loop . . . . . . . . . . . . . . . . . . . . . . . . 17
ESD Protective Measures for Prepress Systems and Operators . . . 18
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Practical Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Standards/Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disposal of the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . . 20
Converting the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . . . 20
Heidelberg online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table of Contents
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Introduction
Description of the Unit and its Functions . . . . . . . . . . . . . . . . . . . . 23
Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
On/Off button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Notes on the Use of Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Notes on Installation
Notes on Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transport of the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . 29
Installation of the Suprasetter . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic Cutouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Software Installation (Container Version) . . . . . . . . . . . . . . . . . . 30
Saving a Backup of the Recorder Configuration . . . . . . . . . . . . . . 31
Selecting the User Interface Language . . . . . . . . . . . . . . . . . . . . 32
Operation
Power-on and Power-off Rules with a Linux Operating System . . . . 33
Power-on order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Shutdown order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Workstation (PC) restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Switching on the Suprasetter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Manual Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Automatic Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Switching off the Suprasetter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Shutdown using the User Interface on the Workstation . . . . . . . . 37
Shutdown with the On/Off button on the Suprasetter. . . . . . . . . . 37
Quick Shutdown with the On/Off button on the Suprasetter. . . . . 39

Table of Contents
Suprasetter 145/162/190 – User’s Guide 5
Material Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Material storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Loading Plates on the Manual Device and on the
Semi-automatic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Unloading the Plates on a Manual Device . . . . . . . . . . . . . . . . . . . 45
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Switching on an Automatic Cutout . . . . . . . . . . . . . . . . . . . . . . 48
Service and Maintenance
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Qualification of the Users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Maintenance by the User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cleaning the Suprasetter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cleaning the Cleaning Roller on a manual Suprasetter and on a
Semi-automatic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cleaning the Cleaning Roller on a Fully Automated Device with a
Cross Conveyor or OLP Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removing Punch Waste on a manual Suprasetter and on a
Semi-automatic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removing Punch Waste on a Fully Automated Device with a
Cross Conveyor or OLP Table . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Changing the Filter Kit in the Suction Device . . . . . . . . . . . . . . . 66
Disposal
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disposal of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disposal of the Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Harmful substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Table of Contents
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Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Disposal of the Loader/Unloader . . . . . . . . . . . . . . . . . . . . . . . . 86
Harmful substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Recyclable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Technical Data
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Protection and Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . 95
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Mechanical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . 96
Interference emission (stray radiation and interference voltage) . 97
Interference immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Radio Interference Suppression . . . . . . . . . . . . . . . . . . . . . . . . . 97
Approvals and conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
CE Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Labels on the Suprasetter 145/162/190 . . . . . . . . . . . . . . . . . . . 99

Before you start ...
Suprasetter 145/162/190 – User’s Guide 7
Before you start ...
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.
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 7.
• 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.
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Before you start ...
8Version2019
Important Information
Important information in the text is indicated by symbols at the side which are
used as follows:
Note: Contains important general or supplementary information about
a specific topic.
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" signal word indicates a hazard with a
medium risk which, if not avoided, can result in death or
severe injury.
Caution
The "CAUTION" signal word indicates a hazard with a low
risk which, if not avoided, can result in minor or moderate
injury.
Notice
The "NOTICE" signal word indicates possible material dam-
age. Non-observance of this notice can cause damage to the
machine.
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Before you start ...
Suprasetter 145/162/190 – User’s Guide 9
Prerequisite: Lists requirements which must be met before the subse-
quent steps can be performed.
Safety Notes
The Suprasetter complies with the safety regulations of the standards and
specifications listed in the "Technical Data" chapter.
Device Names
Intended 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
I/O table PG.021.000F

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.
Servicing work may only be performed by authorized specialist person-
nel. The relevant accident prevention regulations must be observed at
all times.
Warning
Risk of fatal injury from unauthorized opening of the
device
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.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 11
Non-observance of accident prevention regulations can lead to the loss
of accident insurance cover.
Caution
Risk of injury from improper handling
Plate edges can be sharp. You can injure your hands if you
do not wear protective gloves.
Caution
Risk of injury from improper handling
The following loads should not be exceeded: women 15 kg,
men 25 kg.
Warning
Risk of injury if safety system bypassed
The key-operated switch that can be seen after the left 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.

Before you start ...
12 Version 2019
DANGER
Danger! High Voltage!
If cleaning the Suprasetter involves the use of liquids, dis-
connect 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.
Caution
Risk of injury from improper handling
You run the risk of injuring yourself between the insertion/
ejection table and the cross conveyor of the Suprasetter
when printing plates with sharp edges are output. You can
injure your fingers if they are between the insertion/ejection
table and the cross conveyor. Use the protective cover to
avoid this.
Caution
Risk of injury from improper handling
We recommend that you wear the disposable gloves and
light dust mask included in the kit when you are changing
the filters.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 13
Note: After you remove the filters, clean the casing with a vacuum
cleaner. Place the used filters, disposable gloves, dust mask and vac-
uum cleaner bag in a plastic bag, tie the bag up and dispose of it as gen-
eral commercial waste. If you are not sure about disposal procedures,
contact your local waste disposal company 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).
The power switch (red rotary switch) triggers an all-pole cut-off of the Supra-
setter from the power supply.
In an emergency, it is to be used as an emergency cutoff switch for the Supra-
setter.
Emergency Stop Switch
The four emergency stop switches are located behind the panels of the device.
They are designed for an emergency during servicing and must be actuated in
the case of danger.
If one of the emergency stop switches is used, all mechanical motions in the
device are stopped.
Note: The invisible laser beam is switched off whenever a panel is
removed.
On/Off button
The Suprasetter is only de-energized by the On/Off button.
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Before you start ...
14 Version 2019
All connectors and outlets of the service line must be easily accessible at all
times.
You must fully disconnect the Suprasetter from the power supply, for
example, in hazardous situations. To do this, use the power switch or pull out
the power connector.
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.
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.
Note: Servicing may only be carried out by Heidelberg personnel who
have been trained by appropriate laser protection officers for this pur-
pose.
DANGER
Danger! High Voltage!
When connecting or disconnecting the power connector,
make sure that your hands are not wet. Do not pull the con-
nector by the cable. A damaged power cable can cause leak-
age 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.
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Before you start ...
Suprasetter 145/162/190 – User’s Guide 15
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
Risk of injury from improper handling
Never remove covers or any other parts of the casing except
for the work described in the "Service and Maintenance" and
"Troubleshooting" 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
Risk of injury from laser radiation
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 procedures.
When carrying out work as described in the customer docu-
mentation, the user must always adhere to the operating
process stipulated. Protection 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 ...
16 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.
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.
DANGER
Risk of injury if safety system bypassed
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.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 17
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 18) if, for example, a suitable
moment in production allows this.
Start check of safety loop
The check of the safety loop starts after you click this button in the
user interface and confirm again.

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.
Notice
During the test no imaging jobs may be processed! In other
words, no plates must be in the device and no jobs are wait-
ing for processing. You must stop processing beforehand.
This displays the interval until the next regular safety loop
test.

Before you start ...
Suprasetter 145/162/190 – User’s Guide 19
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 ...
20 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 section "Disposal",
page 71.
Converting the Suprasetter 145/162/190
Any conversion work on the Suprasetter 145/162/190 may be performed only
by Heidelberg service personnel.