Technical Manual

Revision
Page 1 of 116 0362M264.A
 Log of Changes Made to This Manual

DESCRIPTION BY PAGES DATE ISSUE

Update to manual to include new contact information,
extended HMI screen explanation, new developer PT100 SEM N/A 21/08/2008 A
probe and pre-heat calibration procedure.

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Item Contents Page
1.0 Heights worldwide litho products contact information 5
1.1 Introduction to the Maya processor 7
1.2 Health and safety recommendations 9
2.0 Installation 11
2.1 Height extension bars (option) 11
2.2 Levelling the machine 12
2.3 Water and waste connection 13
2.4 Mains electrical connection 14
2.5 Connection of the power cable 15
2.6 Installing the chiller 16
3.0 The HMI screen 17
3.1 Engineering password code 17
3.2 Engineering password calculation table 19
4.0 Engineering screens 21
4.1 Process settings 23
4.2 Service utilities 27
4.3 Test menu 29
4.4 M/C Config menu 33
4.5 Settings menu 37
4.6 Exiting the engineering section 43
4.7 Re-enable the password 44
4.8 Guard switch override mode 45
5.0 Maya P HMI processor screen tree 47
6.0 PCB Jumper positions 61
6.1 Test points 61
6.2 DIP Switch setting position 62
6.3 Fuse ratings 63
6.4 Safety circuit by-pass switch 64
7.0 Calibrating the PT100 temperature probe input (PL5) 65
7.1 Calibrating the pre-heat thermocouple inputs 67

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7.2 Calibrating the developer replenishment pump 69
7.3 Calibrating the second developer replenishment pump (option) 69
7.4 Calibrating the interleaf paper detectors (option) 71
8.0 Setting the developer section level switch 77
8.1 In-feed and exit sensor sensitivity adjustment 78
9.0 Replacing the PCB 79
9.1 Selecting the machine identity 80
9.2 Clearing the Memory/Self check procedure 82
9.3 Advanced self test procedure 82
10.0 Upgrading the software 83
10.1 Upgrading the software by exchanging the EPROM 83
10.2 Upgrading the software by using the flash loader programme 83
10.3 Flash loader trouble shooting 87
11.0 Plate setter interface 93
11.1 Mini chiller 97
11.2 Chiller planned maintenance schedule 99
11.3 Functional explanation of the preheat 101
11.4 Carrying out a preheat temperature test 103
12.0 General fault finding 105

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1.0 - Heights World Wide Litho Products Contact Information

Heights UK

Postal Address;
Heights (UK) Ltd
Wainstalls
Halifax
West Yorkshire
HX2 7TJ
UK

Main Telephone Number; + 44 (0)1422 240 914

(Monday~Thursday 08.30~16.45hrs / Friday 08.30~15.30hrs)
Fax Number; + 44 (0)1422 240 589

Customer Support Desk Telephone Number; + 44 (0)1422 231 942

(Monday~Thursday 08.30~16.45hrs / Friday 08.30~15.30hrs)
Fax Number; + 44 (0)1422 240 589
e-mail; mailto:[email protected]

Spare Parts Order Line Telephone Number; + 44 (0)1422 240 914

(Monday~Thursday 08.00~16.45hrs / Friday 08.00~15.30hrs)
Fax Number; + 44 (0)1422 240 018
e-mail; mailto:[email protected]

Heights USA contact information

Postal Address;
Heights-USA Inc
1445 Lower Ferry Road
Trenton
NJ 08628
USA

Main/Technical/Spares Telephone Number; +1 609 530 1300

(Monday~Friday 08.00~16.30hrs. 17.00hrs~18.00hrs please follow instructions on answer phone.
Main/Technical/Spares Fax Number; +1 609 530 9430
Technical Support & Spare Parts e-mail; mailto:[email protected]

Heights (Shanghai) Trading Co. Ltd.

Postal Address;

Room 809, Jin Cheng Mansion

No.511, West Tianmu Road
Shanghai
P.R.C. 200070

Main Telephone Number; + 86 21 6354 1356

Main Telephone Number; + 86 21 6354 1353
Main Fax Number; + 86 21 6354 4890

Technical Support e-mail; mailto:[email protected]

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1.1 – Introduction to the Maya Processor

The Maya 62P & 85P lithographic Ctp plate processors are manufactured by Heights UK
Ltd for distribution worldwide. Its design conforms to the latest safety standards
incorporating all the knowledge and experience gained from over 20 years of successful
manufacturing of previous conventional, thermal and red/green/violet processors. The
Maya provides a high value, quality solution for processing violet Ctp plates. The machines
can be installed as part of an automated plate line allowing communication with the plate
exposing devise or as a stand alone installation. The processor has been designed to be
user friendly with a minimum level of operator maintenance coupled with easy access to all
the internal components.

Please use this manual in conjunction with the full product training provided by Heights UK
Ltd, Heights USA or Heights Asia and the full range of technical documentation which
includes the Operator, Pre-installation, Installation, Electrical drawings and Spare parts
manuals.

Due to Heights Ltd commitment to continual improvement, we reserve the right to change
the specification and technical procedures covering the Maya processor at any time and
without prior notice. If there is any doubt about a specific setting or specification, please
seek advice from Heights.

IMPORTANT NOTICE

The use of this manual must be accompanied by adherence to local and national legal
regulations of the country in which the machine is installed. Failure to comply with health &
safety, electrical, water, waste or chemical handling regulations could result in legal
proceedings being pursued by the country of installations responsible authorities. Heights
UK Ltd and/or associated companies cannot accept liability for any subsequent legal
actions due to contravention of these regulations or for any damage to persons or property
or consequential loss arising from the misuse or modification of this product by
unauthorised personnel.

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1.2 - Health & Safety Recommendations

i. For Health & Safety reasons only authorised and suitably qualified personnel are
to work on the Maya range of processors.

ii. All installation work should be carried out in accordance with the requirements
laid down in the statutory regulations or the national approved codes of practice
(ACOP) applicable to the country of installation.

iii. The machine is designed for processing lithographic printing plates and
must not be modified or used for any other purpose.

iv. Do not climb on the machine or stand on top of it.

v. During normal operation, all covers, guards and doors must be closed and
where appropriate kept locked.

vi. Always isolate from the electrical supply before carrying out maintenance work
on the machine. NOTE: The lid safety switches and emergency stop switches
do NOT isolate the electrical supply inside the machine.

vii. The area around the machine should be kept clean, dry and clear of any waste
material.

viii. Access to the main electrical power isolator and the emergency stop buttons
must not be obstructed.

ix. Lithographic chemicals can be harmful – always refer to the manufacturer’s

Health & Safety Data Sheets. Follow the manufacturer’s directions in the Health
& Safety Data Sheets when handling chemicals, filling tanks and containers or
when disposing of chemicals.

x. Health and safety precautions should always be adhered to when working with
plate processors. The wearing of gloves, goggles and protective clothing (PPE)
is recommended when working in the developer / wash section of the Processor.
These sections contain solutions, which can cause burns, and where bacteria
can be present, which can under certain circumstances cause infection.

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2.0 - Installation

The installation, connection of services and commissioning of the machine must be carried
out by fully qualified technician and where required an electrician to ensure the electrical
connection conforms to local electrical installation laws. The installation site must be clean,
dry, free from vibration and strong enough to support the unit (Maya 62-425Kg / Maya 85-
475kg dry weight). There must also be sufficient room to operate the machinery efficiently.
It is recommended that the machine is at least 600mm from any wall or adjacent
equipment to allow easy access for operation and servicing. The machine can be moved
by using a forklift or pallet truck under the frame or by using the built in wheels (if fitted).

Ensure that the lifting equipment used is rated at a greater Safe Working Load
(SWL) than the maximum weight of the processor.

2.1 - Height Extension Bars (Option)

If the height of the standard Maya P is too low for the on-line equipment it is to be installed
with. Height extension bars can be ordered factory fitted with the Maya P or they can be
fitted on site. If they are to be fitted on-site, a fork lift truck will need to be available to lift
the Maya P sufficiently to allow the levelling feet and wheels to be removed. Fit the bars
using the existing bolts into the base of the machine. The levelling feet and wheels are
then fitted. Do not stand under the machine when it is on the fork lift truck. Take all
necessary safety precautions to ensure your safety! After levelling the machine is
completed (described in the following section), fit the plastic covers to the ends of the bars.

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2.2 - Levelling the Machine

To successfully install the Maya P, it is important to level the machine correctly. To do this,
use a level with a tolerance of 0.5mm/1M. Place the level in the 3 positions shown in the
pictures and level by means of the 4 levelling feet. The adjustment and locking nuts are 24
mm.

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2.3 – Water & Waste Connections

The water inlet (3/4” BSP) is centrally located on the brush drive side of the machine. It is
strongly recommended that a stopcock or gate valve be connected in the supply line at a
convenient point to allow local disconnection of the machine. The minimum water pressure
is 1.4 Bar and the water maximum pressure is 3 Bar. If the water supply is greater than
this, fit a pressure regulator valve. The drainage is provided by a ¾”hose tail fitting located
on the brush drive side. Although a flexible hose can temporarily be connected to this
fitting, it is strongly recommended that a permanent, solid PVC drain be installed to ensure
consistent waste water flow to drain.

The user must provide a water supply and waste connection that complies with
local water authority regulations.

Mains Water
Connection

Waste Connection

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2.4 – Mains Electrical Connection

The electrical cabinet is located on the conveyor drive side of the machine. The door is
locked by means of a special key (supplied) and an interlocked isolator switch.

The Maya P is available in the following versions:

Electrical Technical Specification Maya 62P

Full Load Protected Device Minimum Cable
Specification
Current Rating Size
20A 2 Pole,
230VAC~+/-10% 1W+N+PE 50/60 Hz 21A 8 AWG or 6mm2
C Type MCB
20A 2 Pole,
230VAC~+/-10% 2W+PE 50/60 Hz 21A 8 AWG or 6mm2
C Type MCB
16A 4 Pole,
380-415VAC~+/-10% 3W+N+PE 50/60 Hz 9A 10 AWG or 4mm2
C Type MCB

Electrical Technical Specification Maya 85P

Full Load Protected Device Minimum Cable
Specification
Current Rating Size
20A 2 Pole,
230VAC~+/-10% 1W+N+PE 50/60 Hz 24A 8 AWG or 6mm2
C Type MCB
20A 2 Pole,
230VAC~+/-10% 2W+PE 50/60 Hz 24A 8 AWG or 6mm2
C Type MCB
16A 4 Pole,
380-415VAC~+/-10% 3W+N+PE 50/60 Hz 12A 10 AWG or 4mm2
C Type MCB

Dependant on local regulations, H05VVF3 VDE Approved Type cable is to be used.

The cable sizes shown are a minimum size only. The actual installation wiring size
required should be calculated in accordance with local electrical codes. All
electrical installation work must be carried out by a suitably qualified electrician.

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2.5 – Connection of the Power Cable

1W+N+PE or 2W+PE Installation - Provide a power supply cable into the electrical box. It
is recommended that the power supply is routed through a 2 pole wall mounted isolator
near to the machine so that the machine can be easily, quickly and safely disconnected
from the mains power supply. Connect the wires as shown below. To comply fully with the
EMC certification for the machine, route the mains power cable away from all other cables
in the electrical enclosure.

3W+N+PE Installation - Provide a power supply cable into the electrical box. It is
recommended that the power supply is routed through a 4 pole wall mounted isolator near
to the machine so that the machine can be easily, quickly and safely disconnected from
the mains power supply. Connect the wires as shown below. To comply fully with the EMC
certification for the machine, route the mains power cable away from all other cables in the
electrical enclosure.

After connection but before the machine is powered up. Test that the earth loop
impedance of the earth continuity conductor meets the recognised standard for the country
of installation.

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2.6 - Installing the Chiller

Carefully remove the chiller assembly from the packing box. Locate the 2 black hoses
stored inside the Maya P and connect them to the chiller as shown below. Secure with the
supplied hose clips. Locate the 2 chiller cables stored inside the Maya P and connect the
chiller using the plug and socket. These can only connect in 1 way so cannot be mixed up.
One is for the power supply to the compressor and electrics, the other connection is for the
pump.

Water
Tank System
Fault
Indicator
Level
Indicator &
Drain

Temperature
Controller

Pressure
Switch

Ensure that the level indicator hose is properly positioned (up to the top of the black plastic
holder as shown) and is properly secured. Enter the Engineering SectionÎ Service
UtilitiesÎ Test MenuÎ I/0 TestÎ Set/Clear OP. Scroll down the list to the “Chiller”. Fill
the tank with water slowly continuously checking the level. Stop once the level reaches the
low level mark. Use the “Toggle” button to start the “Chiller” pump. The level of the water
should drop as the hoses and cooling coil are filled. Fill the water up to between the “Min
Level” and “Max Level” marks. Exit all Engineering screens.

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3.0 - The HMI Screen

All adjustable settings on the Maya P processor are inputted via the Liquid Crystal Display
(LCD) Human Machine Interface (HMI) screen. The screens are divided into 2 sections.
Firstly there is the Operator section which displays the current condition of the machine,
the settings which have been inputted into the computer memory and the ability to carry
out every day tasks such as cleaning, sleep mode and plate thickness selection. For more
information on the Operator settings, please refer to the Operator Manual 0362M263.
Secondly there is the password protected section. This is also split into 2 sections; firstly
the Process settings section which allows changes to be made to settings such as
developer temperature and conveyor speed and secondly there is the Engineering section.
This contains screens such as the test menu, language selection, calibration menu and
plate path menu options. All these settings are protected by a 4 digit numeric password
code. How to access the Engineering screens is explained in the next section. The buttons
on either side of the LCD screen execute the commands displayed on the screen.

3.1 - Engineering Password Code

When entering the Engineering section from the Main Menu, you are asked for the 4 digit
password code. This is changed 6 times per day, 365 days a year. The password is
calculated using the table on the following 2 pages. The correct password code is
dependant on the time and date shown on the front screen display. Once the password
code has been entered successfully, this provides access to all parts of the operator and
utility settings within the Engineering Menu.
When the password protected area is exited and the machine reverts to normal operation
mode, you can re-enter the password protected area at any time within the next 60
minutes without re entering the code. Select the re enter option on exiting the Engineering
Menu. Each time you re enter within the 60 minutes, the 60 minutes is re set. After the 60
minutes has elapsed, the code must then be re entered. If, on exiting the Engineering
menu you wish to disable the re entry option, select the no re entry option.

Set Password
1 Exit 0 2

3 1 2 4

5 3 4 6

7 5 6 8

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3.2 – Engineering Password Code Calculation Table

First check that the time and date are correct on the screen.

Hour

First digit Hour Code

The hour of the day divided by 4 00.00-03.59 0
04.00-07.59 1
08.00-11.59 2
12.00-15.59 3
16.00-19.59 4
20.00-23.59 5

Day

Second digit Day Code

st
The remainder when the day of the 1 1
month is divided by 6. 2nd 2
3rd 3
4th 4
5th 5
6th 0
7th 1
8th 2
9th 3
10th 4
11th 5
12th 0
13th 1
14th 2
15th 3
16th 4
17th 5
18th 0
19th 1
20th 2
21st 3
22nd 4
23rd 5
24th 0
25th 1
26th 2
27th 3
28th 4
29th 5
30th 0
31st 1

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Day

Third digit Day Code

The day of the month divided by 6 1,2,3,4,5 0
6,7,8,9,10,11 1
12,13,14,15,16,17 2
18,19,20,21,22,23 3
24,25,26,27,28,29 4
30,31 5

Month

Fourth digit Month Code

Remainder of the month divided by 6 January (01) 1
February (02) 2
March (03) 3
April (04) 4
May (05) 5
June (06) 0
July (07) 1
August (08) 2
September (09) 3
October (10) 4
November (11) 5
December (12) 0

Please note: This information is intended for use by trained technicians

only. It should not be reproduced and distributed to end users.
Unauthorised access to the engineering section by untrained personnel
could result in the processor not functioning correctly, damage to the
processor and the warranty being made invalid.

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4.0 – Engineering Screens

The Engineering Section contains the screens which allow the inputting of data & the
testing of components. To enter this section, use the Engineering password described in
the previous section. The different sections are organised as follows:

Engineering Menu
1 Exit 0277 2

3 4

Process Service
5 Settings Utilities 6

7 8

Please Note;

For information on the Operator Screens, please refer to the Maya P Operator Manual
0362M263.

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4.1 - Process Settings

Within this section all the data such as conveyor speed, Pre-heat temperature, dryer
output & replenishment rates are inputted and settings are saved.

Process Settings
1 Exit 0276 2
Prewash/
3 Developer Menu Rinse/Gum 4

5 Preheat Menu 6

7 Dryer Menu Data Menu 8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

3 – Developer Menu

Processor Speed – Allows the setting of the conveyor motor speed. This may be
done in m/m per minute (or inches per minute if imperial units are selected) or in
seconds, dip to nip (option selectable in M/c Config).
Developer Temperature – Allows the setting of the developer temperature in C° (or
F° if imperial units are selected).
Brush Speed – Allows the setting of the developer brush rotation speed in RPM.
Dev Replen Type – Provides the ability to enter a volume of developer
replenishment per M2 in ml which is automatically added to the developer bath
based on the plate sizes entered in the “Set Plate Sizes” screen or to turn the M2
developer replenishment off.

4 – Prewash/Rinse/Gum Menu

Gum Repl Type – This is no longer used.

5 – Preheat Menu

This menu allows the inputting of individual temperature values for the 4 different plate
gauges available. Each plate gauge setting allows for the 3 zones to be individually set.

0.15 – Selecting this option will allow for the setting of the pre-heat zone settings for
0.15mm gauge plates.
PH Left 1 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.15 gauge plates for the outside left zone.

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 PH Outer (Right) 1 – Enter a value in °C to provide the optimum
temperature measured on the plate for 0.15 gauge plates for the outside right
zone.
PH Inner 1 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.15 gauge plates for the inner zone.
Set Back – This is the temperature drop in °C that the pre-heat zone can
reduce to before the pre-heat starts to heat again. This function stops the
back edge of the plate overheating.
0.20 – Selecting this option will allow for the setting of the pre-heat zone settings for
0.20mm gauge plates.
PH Left 2 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.20 gauge plates for the outside left zone.
PH Outer (Right) 2 – Enter a value in °C to provide the optimum
temperature measured on the plate for 0.20 gauge plates for the outside right
zone.
PH Inner 2 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.20 gauge plates for the inner zone.
Set Back – This is the temperature drop in °C that the pre-heat zone can
reduce to before the pre-heat starts to heat again. This function stops the
back edge of the plate overheating.
0.24 – Selecting this option will allow for the setting of the pre-heat zone settings for
0.24mm gauge plates.
PH Left 3 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.24 gauge plates for the outside left zone.
PH Outer (Right) 3 – Enter a value in °C to provide the optimum
temperature measured on the plate for 0.24 gauge plates for the outside right
zone.
PH Inner 3 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.24 gauge plates for the inner zone.
Set Back – This is the temperature drop in °C that the pre-heat zone can
reduce to before the pre-heat starts to heat again. This function stops the
back edge of the plate overheating.

0.30 – Selecting this option will allow for the setting of the pre-heat zone settings for
0.30mm gauge plates.
PH Left 4 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.30 gauge plates for the outside left zone.
PH Outer (Right) 4 – Enter a value in °C to provide the optimum
temperature measured on the plate for 0.30 gauge plates for the outside right
zone.
PH Inner 4 – Enter a value in °C to provide the optimum temperature
measured on the plate for 0.30 gauge plates for the inner zone.
Set Back – This is the temperature drop in °C that the pre-heat zone can
reduce to before the pre-heat starts to heat again. This function stops the
back edge of the plate overheating.

7 – Dryer menu

Dryer Warm Up – Allows the option to start the Dryer Heater earlier if required.
Input this value in seconds.
Dryer Output – The heater output settable in %.

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8 - Data menu

Save Settings – Selecting this will save the current configuration to memory.
Changes cannot be undone.
Restore Settings – Restores basic configuration settings when an E2 ROM is fitted
from an old board after a PCB change.
Restore Cons data – Restores consumable data when an E2 ROM is fitted from an
old board after a PCB change.

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4.2 – Service Utilities

The selection of screens available within the Service Utilities section of the Engineering
Menu consist of the following;

Service Utilities
1 Exit 0272 2

3 Test Settings 4
Alarm Cancel
5 M/c Config
Time 6
Watchdog Clear
7 Events Process DB
8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

3 – Test Menu

This menu contains screens, which allow for individual operation of components such as
heaters and pumps so that they can be tested individually or included in a group test.

4 – Settings Menu

This menu contains screens, which allow the input of all the machines operating
parameters such as replenishment calibration and heater controls setup.

5 – M/c Config Menu

This menu contains screens, which allow the input of all the machines operating
parameters such as replenishment calibration and heater controls setup.

6 – Alarm Cancel Time

Input the time in minutes that the alarm signal will return after cancelling.

7 - Watchdog Events

A log of all on/off events is kept along with electronic fault codes & data.

8 – Clear Process DB (Data Base)

Selecting this option will re-set ALL data back to default values. All data will be lost.

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4.3 - Test Menu

The Maya processor software comes complete with an on-board set of diagnostic tools for
testing electrical components on the machine. The tests can all be carried out from the
HMI.

Test
1 Exit 0271
Debug
2
Displays

3 I/O Test Heater Ctrl 4

Set Gum
5 Section
Motor Ctrl 6
Setter I/F
7 A to D Test
Test
8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

2 – Debug Displays

In this screen you have the option to select a number of different lines of information which
are displayed on the main screen.

All the screens except Watchdog & Error display a “Show” or “Hide” option. Selecting
“Show” displays the extra line of data on the normal operating screen.

Dose Data – Shows in real time a numerical countdown when the pumps are activated.
Plate Size Display – Displays a line of data which shows the measured length of the plate
as seen by the in-feed sensor. The selected plate size number (as inputted into the Plate
Size table) is also displayed.
Watchdog & Error – This allows the non-reversible clearing of sections of memory.
Clear Open Errors – Clears the Open Errors List in the Alarm History/Open
Alarms.
Clear Error List – Clears the entire error log in the Alarm History.
Clear Watch dog List – Clears the entire Watchdog List.
Clear Unused Change – If the processor displays a warning that a solution or filter
needs changing, but the option to change it is not displayed. This will remove the
warning. This only occurs after a major upgrade in software.
Setter Debug – For Heights use only.
Debug Exit Sensor – Shows the time at which the sensor turns on and at which time it
first detects the plate (off). There is also the option for a re-entry sensor which is not
available on the Maya.

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3 – I/O Test

Here there are 2 options:

Set/Clear OP – Use the “Toggle” button to turn each output component on or off
(I/O).
Display IP - This screen displays all the input components. Activating or de-
activating the component will display the I/O state. Selecting Beep X/I/O will turn off
the bleep, turn it on when the component is activated or turn it on when it is de-
activated.

4 - Heater Ctrl

This allows all the heating components to be tested. There are 5 options:

PH Right Test - Increase or decrease the % output from the right pre-heat zone.
The temperature as monitored by the K-type thermocouples is also displayed.
PH Left Test - Increase or decrease the % output from the left pre-heat zone. The
temperature as monitored by the K-type thermocouples is also displayed.
PH Inner Test – Increase or decrease the % output from the inner pre-heat zone.
The temperature as monitored by the K-type thermocouples is also displayed.
Developer Heater – Increase or decrease the % output from the heater cartridge in
the developer section. The temperature as monitored by the PT100 probe is
displayed.

Important – The developer section must be at least 50% full before this test is
carried out otherwise the heater, tank and PCB will be damaged.

Dryer Heater – Increase or decrease the % output from the dryer heater. The fans
will turn on automatically the heaters are started.

5 – Set Gum Section

This provides the ability to manual start the conveyor and gum pump so that the gum
supply can be regulated for the optimum gum flow rate.

6 – Motor Ctrl

Here there are 2 options:

Drive – The screen allows the selecting of any conveyor speed from 500 mm per
min to 2000 mm per min. The monitored speed from the encoder is displayed. It is
normal for the displayed speed to fluctuate. The screen also displays the volts going
into the motor from the DC drive system and the amps consumed by the motor.
Brush - The screen allows the selecting of any brush rotation speed. The speed
selected is the rotational speed of the first brush, the second brush is slower. The
screen also displays the volts going into the motor from the DC drive system and
the amps consumed by the motor.

7 – A to D Test

This is not used.

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8 – I/F Test

To test the interface relays, enter one of the options shown below:

Test Number Action

0 Error/Fault
1 N RDY (not ready)
2 Warning/Busy
3 Ready

Depending on how the interface has been programmed (see the individual interface
instructions for the particular plate setter) the switching of the relays will be different.

Please note; any combination of tests such as conveyor/brush motors, heaters and output
components can be tested at the same time. Simply change screen to activate or de-
activate the required test components. The IP status can also be monitored at the same
time as output components are be tested.

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4.4 – M/c Config Menu

To select different languages, change & fill options or Imperial units use the M/c Config
menu as follows:

M/c Config
1 Exit 0259
Change &
Fill 2
Languages
3 Offsets and Units 4

Entry Drive Idle

5 Sensors State 6
Reentry Wash
7 Present Section Type 8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

2 – Change & Fill

There are 3 options in this menu;

Fill Times Menu – These screens allow the input in seconds of the maximum time
the fill functions will operate before being automatically stopped and the time in
seconds that the pumps will continue to operate once the float switch has been
activated.

Change Menu – These screens allow the input in M2 of plate material and days the
maximum period that the developer, developer filter or wash water (when in
recirculation mode) can be used. When the M2 or days (whichever comes first) has
been exceeded, an alarm will be displayed on the HMI and the machine will be put
into a “Warning” state telling the user to change that particular solution or filter.

Set Dual Replenish – Selecting “Dual Pump” activates the electrical function for 2,
independently controlled developer replenishment pumps. This is usually set to
“Normal” for a single replenishment pump unless informed otherwise.

3 – Offsets

There are 6 options in this menu:

Dev Temp Offset – This allows for the displayed temperature to be modified by +/-
2° C. This is used when the processor temperature is required to match a hand held
devise regardless of actual temperature.

Page 33 of 116
 0323C676.1/.2 – This function is no longer used. Ensure that the option
“0323C676.3 up” is selected.
Preheat Type – This allows the option to select either 2 zone or 3 zone preheat
types. Always select 3 zone.
Chiller Restart Delay – This is no longer used.
Reset PDI Flag – This resets the PCB into PDI (Pre Delivery Inspection) mode for
setup and component testing. I list of test point shortcuts are displayed. Only select
this under the guidance of Heights. If it is selected by mistake, scroll to the bottom
of the list and select “End PDI”. This will return the machine back to normal
operating mode.

4 – Languages & Units

There are 7 options in this menu:

Plate Speed – Select between the option of metric (m/m) and Imperial (inch/min) as
required.
Temperature – Select between the option of Metric (C°) and imperial (F°) as
required.
Replen Rate – Select between the option of Metric (ml) and Imperial (floz) as
required.
Date Style – Select between the option of the international date style dd/mm/yyyy
and the US date style mm/dd/yyyy.
Language – Select the required language from those listed. The translations only
apply to the operator screens.
Speed Display Type – Select between the 2 conveyor speed setting options of
m/m per min and the dip to nip time in seconds.
Plate Count – If a PCB has had to be changed, the new board will show zero on
the total plate counter and M2. To display the old plate count and M2 information in
the new PCB, input the total number of plates processed and the M2 plate area into
these screens and the board will record the new settings.

5 – Entry Sensors

This option allows for the fitting of dual input sensors. This option is not currently available
on the Maya P. Selecting 2 sensors does however disable the exit sensor if required.

6 – Drive Idle State

Select the required option between the conveyor motor continuously crawling (rolling) or
for the conveyor to stop after each plate is processed. Always set to Rolling.

7 – Re-entry Present

This option allows for a re-entry facility to be added to the machine. This option is not
currently available on the Maya P. Always set to No Reentry.

Page 34 of 116
8 – Wash Section Type

As standard the Maya P is configure for direct to drain rinse water. However there is an
option to fit a water saving system comprising of a water recirculation pump and additional
hoses. To select either system follow the on-screen instructions. Currently internal water
recirculation is not available so this function is not available. External water recirculation is
available and does not require this function to be activated.

Page 35 of 116
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intentionally left
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Page 36 of 116
4.5 – Settings Menu

Settings
1 Exit 0266 Autorun Menu 2

Set Heater
3 Motor Setup
PI Constants
4

Plate Path Plate Setter

5 Menu Menu 6
Temperature Calibration
7 Limits Menu 8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

2 – Autorun Menu

Anti Ox Menu – These options programme the hourly anti ox replenishment:

Anti Ox Type – Select Timed Anti Ox. Do NOT select Averaging Anti Ox.
Operational Volume – The volume of developer in ml (or fl/oz if
imperial units are selected) added to the developer bath per Anti Ox
Period when in normal operation mode.
Close Down Volume - The volume of developer in ml (or fl/oz if
imperial units are selected) added to the developer bath per Anti Ox
Period when in Close Down or Sleep mode.
Anti Ox Period – The time settable in minutes between each Anti Ox
cycle.
Delay Anti Ox – Select “Always”.
Auto Run Time - Allows the adjustment in minutes between Auto Run cycles when
in Operational mode. Auto Run cycle consists of the motors & pumps turning on for
a set period (settable in Auto Run Length).
Auto Run Length – The duration of the Auto Run Time settable in seconds.
Configure Sleep – This is a series of screen that sets up the function of the Auto
Run when in Close Down/Sleep mode. The screens are displayed sequentially.
Close Down Exercise Time - The duration of the Auto Run Time settable in
seconds.
Close Down Exercise Interval – The adjustment in seconds between Auto
Run cycles.
Close Down Circulation – Allows the option of running the pumps or not
during the Auto Run cycle.
Rinse/Wash Spray Bars – Allows the option of turning on the spray bars
during the Auto Run Cycle.
Close Down Anti Ox – Allows the option to turn the Anti Ox function on or
off during the Close Down/Sleep mode.

Page 37 of 116
3 – Motor Setup

There are 8 options in this menu:

Drive I Limit – This is the amps threshold at which the electronic control of the
motor shuts the power supply down due to an overload condition. This should be
left at the default value unless instructed by Heights to change it.
Drive Smoothing – Do not adjust.
I Limit Shutdown – This is the number of pulses or tick that the encoder produces
during an overload condition before the power is cut off.
Brush Speed Scaling – To ensure that the brush motor is rotating the developer
brushes at the same speed that is displayed on the screen. The brush speed
scaling is used to calibrate the true RPM. The rotational speed of the first developer
brush is measured either by using a tachometer or by simply counting the rotations
of the brush per minute. If the rotational speed of the brush is too slow, increase the
brush speed scaling value slowly (by 0.1 increment per change). If the rotational
speed of the brush is too fast, de-crease the brush speed scaling value slowly (by
0.1 increment per change). Exit all screens to finish the process.
Brush I Limit - This is the amps threshold at which the electronic control of the
motor shuts the power supply down due to an overload condition. This should be
left at the default value unless instructed by Heights to change it.
Brush Smoothing – This controls the brush motor drive characteristics. Do not
adjust.
Brush Armature Resolution – This controls the brush motor drive characteristics.
Do not adjust

4 – Heater PI Constants
.
There are 5 options available:

Dev – The KP, KD & KI should not be adjusted under normal conditions. However,
when the “Dev” screen is displayed the heater automatically turns on and will run
normally stabilising the developer temperature if there is demand for developer
heating. This screen can be used to monitor the heater for correct operation.
Ensure that the developer heater cartridge is fully covered with liquid before using
this screen.
Chiller - The KP, KD & KI should not be adjusted under normal conditions.
However, when the “Chiller” screen is displayed the chiller automatically turns on
and will run normally stabilising the developer temperature if there is demand for
developer cooling. This screen can be used to monitor the chiller for correct
operation.
Preheat Outer (Right) - The KP, KD & KI should not be adjusted under normal
conditions. However, when the “Preheat Outer (Right)” screen is displayed the
ceramic tiles in that zone automatically turn on and run normally stabilising the
preheat temperature selected on the main operation screen if there is demand for
the tiles to heat. This screen can be used to monitor the ceramic tiles for correct
operation.
Preheat Outer Left - The KP, KD & KI should not be adjusted under normal
conditions. However, when the “Preheat Outer (Left)” screen is displayed the
ceramic tiles in that zone automatically turn on and run normally stabilising the
preheat temperature selected on the main operation screen if there is demand for

Page 38 of 116
 the tiles to heat. This screen can be used to monitor the ceramic tiles for correct
operation.
Preheat Inner - The KP, KD & KI should not be adjusted under normal conditions.
However, when the “Preheat Inner” screen is displayed the ceramic tiles in that
zone automatically turn on and run normally stabilising the preheat temperature
selected on the main operation screen if there is demand for the tiles to heat. This
screen can be used to monitor the ceramic tiles for correct operation.

5 - Plate Path Menu

The 4 options in this menu are:

Disable Pre-heat – This must always be set to “Pre-Heat Enabled”.

Plate Path – The on/off timing of each component such as pumps, solenoid valves
and motors are controlled from this menu. Selecting “Plate Path” displays a list of all
the on/off functions used in the automatic operation of the machine. The timing
values of all functions are entered in m/m and all values are measured from the
entry sensor. The function on timings, all reference the front edge of the plate; the
function off timings all reference the rear edge of the plate. These settings do not
normally require adjusting.
Encoder Step – This is the numeric value set in microns that the plate travels per
encoder pulse.
Length Adjustment – When using the “Plate Length” option in “De Bug Displays”,
depending on the position of the on sensor the plate length displayed may be
consistently incorrect. This screen allows an inputted value in m/m to either subtract
or add to the displayed value. This is only ever used when the machine is on-line
and automatically fed.

6 – Plate Setter Menu

The options available in this menu allow for a range of interface types that are not all
available for the Maya 85T. However a description is provided for all the options displayed.

Select Setter Interface – This allows for the appropriate interface type to be
selected. These include:
No Setter – No communication is available. Also the conveyor start is
delayed by 2 seconds when a plate is placed over the on sensor to allow for
the plate to be positioned correctly.
Fuji – This is for an RS232 bi-directional serial connection dedicated for use
with FFEI/FujiFilm engines.
Python – This is for an RS232 bi-directional serial connection dedicated for
use with the Highwater Python engine.
External Unit – This is for a bi-directional, programmable interface (for
further information, see the section on interfaces, the information below or
contact Heights for dedicated interface instructions). This function requires
optional hardware.
User – This is for a uni-directional, programmable interface (for further
information, see the section on interfaces, the information below or contact
Heights for dedicated interface instructions). This function requires optional
hardware.
Configure User Setter – When “User” is selected from the “Select Setter Interface”
menu, this screen provides options for the 2 bit signal switching to be programmed.

Page 39 of 116
 For further information, see the section on interfaces or contact Heights for
dedicated interface instructions.
Configure External Interface – When “External Unit” is selected from the “Select
Setter Interface” menu, this set of 2 screens provides options for the 4 bit input and
output switching/signal generation to be programmed. For further information, see
the section on interfaces or contact Heights for dedicated interface instructions.
External Interface by Code – This is an 8 digit code that when entered into this
screen, will automatically configure the I/0 of the external unit interface.
Configure Error Codes – This should not normally require changing. For further
information, see the section on interfaces or contact Heights for guidance on any
specific interface requirements.

7 - Temperature Limits

Temp Limit Check – The 2 options available here are:

Enabled – The +/- tolerance entered into the Dev Temp Limits and Preheat
Temp Limits are active and will automatically control the function of the
processor.
Disabled – The +/- tolerance entered into the Dev Temp Limits and Preheat
Temp Limits are disabled. This means that regardless of the temperature of
either the Dev Temp or Preheat Temp, the processor will accept a plate and
process it automatically. Always reset to Enabled after use to ensure correct
processing of a plate. This setting is also automatically reset to Enabled
when the processor is electrically isolated. The next time the processor is
powered up, the Temp Limit Check will have been enabled.
Dev Temp Limits – This setting provides a +/- (upper and lower) tolerance limit on
the developer bath temperature. If the actual temperature exceeds either the upper
or lower limit the machine will go into a “Not Ready” condition and only return to a
“Ready” condition when the temperature has stabilised within the upper and lower
limits. This is settable in C° in increments of 0.1 C°.
Set Plate Change Delay – This option allows for a time delay to be entered to allow
the preheat to stabilise when changing plate gauge. A different time value can be
entered for an increase in temperature or a decrease in temperature. Ex factory this
is set to zero for both an increase and decrease in temperature.
Preheat Soak Times – This option allows for up to 4 programmed Soak Times to
be entered. The Mins Off is the period of time that the machine has been stopped or
powered down and the Mins Soak is the corresponding period of time that the
processor will wait from first displaying Ready before a plate can be processed. For
example, if 5 minutes is entered into Mins Off and 2 minutes is entered into Mins
Soak, if the processor has the top covers off for more than 5 minutes, once the
machine has preheat and developer have stabilised at the correct temperature, it
will be 2 minutes before a plate can be processed. Normally an escalating set of
values will be entered such as 5, 10 20 and 30 minutes with corresponding periods
of stabilisation time. Ex factory all values are set to zero.
Preheat Soak Debug – This allows the displaying on the front screen values for
analysing the operation of the Preheat. Do not use.
Preheat Cooling – This allows the setting of the temperature at which the preheat
cooling fans start to work. On the Maya P this function is no longer used.
Preheat Temp Limits – This setting provides a +/- (upper and lower) tolerance limit
for all 3 zones of the preheat temperature. If the actual temperature exceeds either
the upper or lower limit the machine will go into a “Not Ready” condition and only

Page 40 of 116
 return to a “Ready” condition when the temperature has stabilised within the upper
and lower limits. This is settable in C° in increments of 0.1 C°.

8 – Calibration Menu

Cal PT100 Dev – For further information on this option please refer to the section
“Calibrating the PT100 temperature probe input (PL5)” later on in this manual.
Preheat Calibration – Options are provided to calibrate all 3 K-Type thermocouple
inputs on the board. For further information please refer to the section “Calibrating
the K-Type Thermocouple Preheat Temperature Inputs PL6/7/9”.
Replenish Calibration - For further information on this option please refer to the
section “Calibrating the Developer Replenishment Pump” later on in this manual.
Cal Bulk Dev Replen – This option is only displayed when Dual Replenish Pumps
have been fitted and selected in the M/C Config Menu. For further information on
this option please refer to the section “Calibrating the Second Developer
Replenishment Pump” later on in this manual.
Read System Data – Read System Data reads all the data from the removable
EEROM (IC12) if you have to change a board. You need to perform a read in the
first few minutes, or the data will get overwritten.

Page 41 of 116
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intentionally left
blank

Page 42 of 116
4.6 - Exiting the Engineering Section

EEPROM Update
1 Exit 2415 2

3 4
Save Any Change Made
To EEPROM Memory
5 6

7 Quit Continue 8

To exit the engineering section, exit all the engineering screens until the following screen
is displayed;

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

7 – Quit

Selecting this option will immediately discard any changes made and will exit the
engineering section to the “Reenable Password” screen.

8 – Continue

Selecting this option will save all changes made to the engineering section. Once this
option has been selected, all changes are non reversible. After selecting “Continue” there
will be a flash screen (2402) displayed confirming the changes. This automatically
disappears after 3 seconds. The “Reenable Password” screen is then displayed.

Page 43 of 116
4.7 – Re-enable Password

Reenable Password
1 Exit 2411 2

3 4
Enable After 1 Hour
Enable Password NOW
5 Up 6

7 Down 8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

5 – Up

Moves the selection up

7 – Down

Moves the selection down.

Enable After 1 Hour – You may re-enter the engineering section without re-
entering the current password for the next 1 hour. After 1 hour the password will be
re-set and the current password will need to be entered to gain access to the
engineering section. If you re-enter the engineering section within the 1 hour, when
you exit you may select “Enable After 1 Hour” again.
Enable Password NOW – Immediately re-sets the password. To re-enter the
engineering section, enter the current password.

Page 44 of 116
4.8 - Guard Switch Override Mode

To enable “Guard Switch Override Mode” place the supplied key into the key switch
mounted on the electrical panel door as shown below.

Normal Guard
Operation Switch
Switch Override
Position Position

Rotate the key to the Guard Switch Override position. The screen shown below will be
displayed. The machine will not now process plates automatically but it will keep the
developer temperature stable.

Guard Switch Override

1 Exit/
Restart 0151 Fill Tanks 2

3 Inch Back Hold to Run 4

Cancel
5 Inch Forward
Plate 6

7 Engineering 8

1 – Exit (or Return)

Selecting this button (as with all other screens) goes back to the previous screen.

Page 45 of 116
2 – Fill Tanks

Select from the options available – Dev Fill (option). Selecting this option will start the
developer fill pump. They will run until;

a) The developer float switch is activated indicating that the tank is full.
b) The developer max fill time is reached (See M/c config section, Change & Fill).
c) The button is depressed a second time to stop the pump.

3 – Inch Forward

Using this button will start the conveyor motor to drive the conveyor in the normal direction.
Releasing the button will stop the motor.

4 – Hold to Run

This function allows a plate to be made automatically with the top cover removed, however
the button must be continually depressed for this to work. Releasing this button will stop
the process immediately. Also, the processor must be in an OK condition to make a plate,
for example; the developer must be up to the float switch and the temperature must be
within the normal working tolerance for both the developer and the preheat.

5 – Inch Back

Using this button will start the conveyor motor to drive the conveyor in the opposite to
normal direction. Releasing the button will stop the motor

6 – Cancel Plate

Selecting this option will cancel all plates currently being processed.

8 – Engineering

Selecting this option will prompt you for the current engineering password. See the section
on the engineering password code calculation table.

Page 46 of 116
5.0 - Maya P HMI Processor Screen Tree

Software Version 05.01.09

Display Version 02.45 Winstar

Page 47 of 116
 Turn M/c ON
A
Startup Display

Plate Count Reset

Auto Run
Go To
L
Guard Switch
Override Menu Main Operation Display Active Alarms

Main Menu This screen changes

Rotate Service Plate Thickness automatically depending
on whether the machine
Key To Enter is on-line or off-line

Operator Change System Closedown/ Conveyor/Drive Engineering

Settings Menu Summary Sleep Menu Menu Menu

Go To Go To Go To Go To Go To
B C D E F This screen is
password protected.

Go To
G

Page 48 of 116
 Operator
B From
A Settings

Fill Set Plate Sizes Manual Replen Screen Saver Data

Tanks Menu Menu

Developer Manual Dev Save Settings

Replen

Manual Gum Restore Settings

Replen

Restore Cons
Data

NOT
Manual Gum
Replen
USED

Page 49 of 116
 Change
C From
A Menu

Change Change Fill

Developer Dev Filter Tanks (Option)

Developer
From System
D A Summary

Summary Summary Alarm Menu

Processing Consumables

Developer Alarms

Cancel
Alarm

Alarm
History

Open
Alarms
Page 50 of 116
 From Sleep/Close
E A Down Menu

Set Sleep/ Set Warm up End Sleep/ Set

Close Down Times Close Down Clock

Conveyor
F From
A Menu

Restart Inch Inch

Stop
Conveyor Forward Back

Cancel Plate

Page 51 of 116
 G From
A
Engineering
Menu

Process Service Go To
Settings Utilities H

Developer Pre Heat Dryer Pre-Wash Save

Menu Menu Menu Rinse/Gum Settings

Processor Go To
Speed G1 Dryer Gum Repl Save Settings
Warmup Type
Developer
Temperature
Dryer
Restore Settings
O/P
Brush Speed

Dev Replen NOT

Manual Gum Restore Cons
Replen
Type USED Data

Page 52 of 116
 From Pre Heat
G1 G Menu

0.15 0.20 0.24 0.30

PH Left PH Left PH Left PH Left

PH Right PH Right PH Right PH Right

PH Inner PH Inner PH Inner PH Inner

Set Back Set Back Set Back Set Back

Page 53 of 116
 From
H G
Service Utilities

Watchdog Alarm Cancel

Test M/C Config Settings
Events Time

Go To Go To Go To
I J K
Clear
Process DB

This menu This menu This menu

contains screens, contains screens, contains screens,
which allow for which set the which allow the
individual basic operating input of all the
operation of configuration of machines
components such the machine and operating
as heaters and how the EMS parameters such
pumps so that screen displays as replenishment
they can be tested information. calibration and
individually or heater controls
included in a setup.
group test

Page 54 of 116
 From
I H
Test

I/O Set Gum A to D De Bug Heater Motor Setter I/F

Test Section Test Display Control Control Test

Plate Size
Set/Clear Start Display PH Right
Drive
OP Drive Test

Setter
Debug
Display Start Gum PH Left Brush
IP Pump Test
Debug Exit
Sensor
Clear Open
Errors PH Inner
Debug Exit Test
Sensor
Clear W/Dog
List
Watch Dog Dryer
& Error Heater
Clear Error
List
Dose
Data Developer
Clear Unused Heater
Change
Page 55 of 116
 From M/C Config
J H

Entry Wash Section Languages & Change Re Entry Drive Idle

Offsets
Sensor Type Units & Fill Present State

Dev Temp Plate

Offset Speed

Re Set PDI Temperature

Fill Times Change
Flag
Plate Menu Menu
Count
Language Max Dev Fill Dev Change
0323C676
Time
.1/.2

Dev Over Fill Dev Filter

Replen Time Change
Chiller Restart Rate
Delay
Set Dual
Date Replenish
Preheat Style
Type
NOT
Manual Gum
Speed Display
Replen
USED Type

Page 56 of 116
 From
K H
Settings

Motor Plate Path Temperature Auto Run Set Heater P/I Plate Setter Calibration
Setup (*) Menu Limits Menu Constants Menu Menu

Drive I Plate Dev Temp Select Cal. PT100

Limit Path Limit Go To Setter I/F Dev (PL5)
K2
Drive Encoder Pre Heat Configure Pre Heat
Smoothing Step Soak Times User Setter Calibration

Brush Preheat Pre Heat Configure Read

Speed Scaling Disable Cooling Error Levels System Data

Brush I Length Temp Limit Anti Ox Go To Configure Replenish

Limit Adjustment Check Type K1 External I/F Calibration

Brush Set Plate Configure Go To External I/F

Smoothing Change Delay Sleep K3 By Code
Please set length
adjustment to “0”.
Brush Otherwise please Pre Heat Auto Run
Armature Res refer to HMI Soak Debug Time
screen description
(*)Only adjust motor setup screens under factory
I Limit Pre Heat Auto Run advice.

Shutdown Temp Limits Length

Page 57 of 116
 From Anti Ox
K1 K Type

Averaging Timed
Anti Ox Anti Ox

Daily Replen Operational

Volume Volume

Do NOT use Averaging Anti Ox

Averaging Anti Ox Period Period
option. Always use
the Timed Anti Ox
Replenish Sleep/Close
option Down Volume
Summary

Min Replen Delay

Volume Anti Ox

Samples /
Average

Page 58 of 116
 From
L A Guard Switch
Override Menu

Exit/Restart Inch Inch Fill Tanks Cancel Engineering

Hold to Run
Back Forward Menu (Option) Plates Menu

Developer Go To
G

From Configure
K3 K Sleep

Close Down Close Dn Close Dn Rinse/Wash Close Dn

Exercise Time Exer’s Interval Circulation Spray Bars Anti Ox
me

Page 59 of 116
 Set Heater Only adjust under
K2 From
K P/I Constants factory advice.

Dev Pre Heat Pre Heat Chiller Pre Heat

Outer (Right) Outer (Left) Inner

Change Kp Change Kp Change Kp Change Kp Change Kp

Change Kd Change Kd Change Kd Change Kd Change Kd

Change Ki Change Ki Change Ki Change Ki Change Ki

Page 60 of 116
6.0 - PCB Jumper Positions

Jumper positions J1~J8 as seen with the board in normal orientation, fuses to the top.

Jumper No. Illustration Function

J1 Normal position (pins 1&2). Memory OK.
J1 Memory discharge position (pins 2&3).
J2 Option. EPROM enabled position (pins 1&2).
J2 Option. Flash enabled position (pins 2&3).
J3 ------------- No longer fitted to the board.
J4 Normal running position.
J4 Self test and memory erase position (pins 1&2).
J5 Normal running position.
J5 Bootstrap loader position (pins 1&2).
J6 Normal running position. RS232 interface setting (pins 2&3).
J6 RS485 interface setting (pins 1&2).
J7 Option. Normal position (pins 1&2).
J7 Option. Half wave rectification for Gormann Rupp pumps.
J8 Option. Normal position 230 VAC output (pins 1&2).
J8 Option. Half wave rectification for Gormann Rupp pumps.

6.1 - Test Points

Test points TP1~TP8

Test Point no. Output

TP1 0 VDC
TP2 + 24 VDC Unregulated (13~26 VDC).
TP3 - 24 VDC Unregulated (13~26 VDC).
TP4 + 12 VDC Regulated.
TP5 +5 VDC Regulated.
TP6 - 12 VDC Regulated (option for the conductivity probe if required).
TP7 + 65 VDC Unregulated (High voltage DC motor drive)*.
TP8 + 15 VDC Regulated (To drive the motor drive IC)*.

* Both TP7 & TP8 are powered off the same line.

Page 61 of 116
6.2 – DIP Switch Setting Positions

On fitting a new board it is recommended that the following DIP switch settings are
checked and if required, set. To access the DIP switches please carefully remove the
protective film over the switch assembly if fitted.

Not Used Option Maya P

PL9 PL9
SW1 Positions
Pressure Sensor Mode Thermocouple Mode
1 a OFF / OPEN ON / CLOSED

2 b ON / CLOSED OFF / OPEN

3 c OFF / OPEN ON / CLOSED

PL10 PL10
Conductivity Mode Thermocouple Mode
4 d OFF / OPEN ON / CLOSED

5 e OFF / OPEN ON / CLOSED

6 f ON / CLOSED OFF / OPEN

7 g ON / CLOSED OFF / OPEN

8 h OFF / OPEN ON / CLOSED

Page 62 of 116
6.3 - Fusing (Issue B)

Fuse
No. Description Rating (A) Rating (B)
F01 Chiller/Compressor 1AT 1AT
F02 Drier Fan 1AT 1AT
F03 Pre-Wash Recirculation Pump or Solenoid 2AT 2AT
F04 Vacant 2AT 2AT
F05 Second Developer Replen Pump (option) 1AT 1AT
F06 Dev Circulation Pump 1AT 1AT
F07 Vacant ---------------- ----------------
F08 Vacant ---------------- ----------------
F09 Vacant ---------------- ----------------
F10 Gum Recirculation Pump 1AT 1AT
F11 Rinse Recirculation Pump or Solenoid 2AT 2AT
F12 Vacant ---------------- ----------------
F13 First Developer Replen Pump 1AT 1AT
F14 Vacant ---------------- ----------------
F15 Vacant ---------------- ----------------
F16 Vacant ---------------- ----------------
F17 Vacant ---------------- ----------------
F18 PCB Main AC Power Supply 1AT 1AT
F19 Not Available ---------------- ----------------
F20 Not Available ---------------- ----------------
F21 65VDC Motor Power Supply 6.3AT ----------------
F22 Not Available ---------------- ----------------
F23 TR1 Power Supply 6.3AT 6.3AT
RCCB1 RCB 100mA Trip (option) 1 Phase Machine 40A
RCCB1 RCB 100mA Trip (option) 3 Phase Machine 25A
CB1 Pre-Heat Oven 16A
CB2 Developer Heater 6A
CB3 Drier Heater 10A
CB4 Cooling Fans & PCB Outputs Supply 10A

Please note: The item RCCB1 is not fitted to all machines. When it is fitted
the rating of the device depends on whether the machine is for 1 phase or 3
phase installation.

Page 63 of 116
6.4 - Safety Circuit By-Pass Switch

To assist in the maintenance of the Maya P processor and make access easier, a by-pass
switch has been fitted to the electrical cabinet. When the cabinet door is opened, the 1 or 2
(depending on the type of machine) switches are released and the safety circuit/s are de-
activated. The main isolator can then be rotated manually to turn the machine on. This
permits the technician to work on and test the machine with the top cover off the machine.

It is absolutely forbidden under Health & Safety law to by-pass safety circuits during
the normal operation of the machine by the customer. This function is only for use
by fully trained technicians and under no circumstances is information on this
function to be passed to the customer. This function must be de-activated as soon
as possible and all safety features fully operational before the customer starts to
operate the machine. Heights accept no responsibility for mis-use of this function or
the by-passing of safety functions on this machine.

Page 64 of 116
7.0 – Calibrating the PT100 Temperature Probe Input (PL5)

Under normal conditions, the board will not require calibrating for the PT100 input (PL5).
This is because the calibration is done during the manufacturing process of the board
when the calibration values are entered into the board’s E2 ROM memory. However the
following information is provided as a safeguard against unforeseen corruption of the
board’s memory. To help with the re-calibration process, please order a calibration tool
P/N 0323K958 (Fig.1). This will assist in the quick re-calibration of the board.

110 ohm

Toggle
switch
B

105 ohm

Plug A

Fig.1

Go to the calibration menu. This menu can be found in the Engineering section > Settings
> Calibration Menu. Select Cal PT100 Dev. Please note that continuing the calibration
process from this point will destroy all previous settings. These old settings cannot be
restored once overwritten. You must have the correct calibration tool to continue (Fig.1).
Remove the Dev Temp Sensor plug connected onto PL5 (Fig.2).

Fig.2 Fig.3

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Connect the plug “A” (Fig.1) to PL5 (Fig.3). Select 105 with the toggle switch “B” (Fig.1). It
is VERY important that you wait 30 seconds from this point before doing anything else.
Now you can follow the on screen instructions by pressing any key. Once the 10 seconds
sample time has finished, the on-screen instructions will request the 110 position is
selected using the toggle switch “B” (Fig.1). Select 110 and again wait 30 seconds. Now
follow the on screen instructions and press any key. Once the 10 seconds sample time
has finished the following screen will be displayed:

Cal Dev Probe

1 2
Connect 105R (12.8degC)
Any key when ready
V12.8: 16226
3 4
Connect 110R (25.7degC)
Any key when ready
5 V25.7: 16994 6
Gradient: 0.16753
Offset: -2590.21
7 8

Please note that the values shown here are for illustrative purposes only and may not be the same on your machine.

If the Gradient and Offset values are displayed as “+INF and -INF” then some part of the
calibration procedure has failed and the process needs to be repeated. Take care that the
calibration tool is correctly connected to PL5.
Once the calibration procedure has been completed, exit this screen. To confirm that the
calibration process has been successful, exit the Engineering menu to the front operational
screen. Check that the “Act” temperature value is 12.8°C (*) when the 105Ω position is
selected on the calibration tool and that 25.7°C (*) when the 110Ω position is selected.
Remove the calibration tool and replace the PT100 plug onto PL5.
(*)+/-0.2°C is an acceptable tolerance.

Alternatively, if the tool 0323K958 is not available, connect the resistor 105 ohm and 110
ohm as shown below onto PL5 when requested during the calibration process instead of
using the toggle switch “B”. Otherwise the calibration process is the same as previously
described.

Pin Numbers PL5 Pin Numbers PL5

4 3 2 1 4 3 2 1

105 ohm resistor (0.1%) 110 ohm resistor (0.1%)

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7.1 - Calibrating the Pre-heat Thermocouple Inputs

Under normal conditions, the board will not require calibrating for the K-type thermocouple
inputs (PL6~PL10). This is because the calibration is done during the manufacturing
process of the board when the calibration values are entered into the board’s E2 ROM
memory. However the following information is provided as a safeguard against unforeseen
corruption of the board’s memory.

There is a wide choice of K-type thermocouple calibration device available, however

Heights UK can provide a unit; P/N 7267-846. A typical unit is shown below.

Fig.4

Go to the calibration menu. This can be found in the Engineering section > Settings >
Calibration Menu > Cal Pre-Heat. From here select one of the 3 options, Outer Left, Outer
Right or Inner. This refers to the 3 temperature control zones within the pre-heat box (left
to right orientation as seen from the plate input slot). Please note that continuing the
calibration process from this point will destroy all previous settings. These old settings
cannot be restored once overwritten. You must have the correct calibration tool to continue
(Fig.4). Remove the appropriate plug from the side of the electrical box TC sockets (Fig.5).
These are numbered TC1 - Outer Right (PL6), TC2 - Inner (PL7), TC3 - Outer Left (PL9).

Fig.5

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For example, if the outer left requires calibrating, select Outer Left from the screen options.
Plug in the calibration device lead (2 blade thermocouple plug) into the TC-3 Outer Left
socket. When prompted, select 200°C output from the calibration device. It is VERY
important that you wait 10 seconds from this point before doing anything else. Now you
can follow the on screen instructions by pressing any key.
Once the 10 seconds sample time has finished, the on-screen instructions will request the
700°C output from the calibration device. Select 700°C and once again, wait 10 seconds.
Now you can follow the on screen instructions by pressing any key. Once the 10 seconds
sample time has finished the following screen will be displayed (Cal Preheat Left is used
as an example).

Cal Preheat Outer Left

1 2
Simulate 200.0degC
Any key when ready
V200.0: 38879
3 4
Simulate 700.0degC
Any key when ready
5 V700.0: 56038 6
Gradient: 0.29139
Offset: -9507.04
7 8

Please note that the values shown here are for illustrative purposes only and may not be the same on your machine.

If the Gradient and Offset values are displayed as “+INF and -INF” then some part of the
calibration procedure has failed and the process needs to be repeated. Take care that the
calibration device lead is correctly connected to the TC input socket. Once the calibration
procedure has been completed, exit this screen. To confirm that the calibration process
has been successful, exit the Engineering menu to the front operational screen. Check that
the “Act” temperature value of the calibrated pre-heat zone is 700°C (*) when the
calibration device is set to output 700°C. Remove the calibration device from the TC input
socket and replace the thermocouple plug onto the TC input socket.
(*) +/- 3°C is an acceptable tolerance.

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7.2 - Calibrating the Developer Replenishment Pump.

For the Developer replenishment setting, using an accurate measuring jug (10ml
graduations) and place the replenishment/fill spear into the jug filled with developer. Note
the amount of developer in the jug. Go to the Engineering section Ä Settings Ä
Calibration Menu. Select Cal Dev Replen. Follow the on screen instructions. Enter the
quantity of developer that was pumped out of the jug in the 30 second test period. Save
the setting.

Clear
Replenish
Tubing
Developer
Replenish
Probe

Measuring Cylinder
with replenish probe
inserted

7.3 – Calibrating the Second Developer Replenishment Pump

If the optional second developer replenishment pump is fitted. The calibration process is
the same as the normal developer replenishment calibration as described in section 8.1.
However the calibration screen that needs selecting is as follows: Go to the Engineering
section Ä Settings Ä Calibration Menu. Select Cal Bulk Fill Replen. Then follow the
instructions as above.

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7.4 – Calibrating the Interleaf Paper Detectors (Option)

Overview

The interleaf detection system fitted to the Maya processor is normally a factory fit option.
However the parts can be fitted in the field if required, P/N 0323B961. The kit consists of 2
fibre optic sensors as shown below and 2 amplifier units fitted inside the electrical box.

Function

As the plate passes over the In-feed (On) sensor the encoder counts 10mm from the
On/start position. At 10mm the Interleaf paper detectors (top & bottom) are activated (the
PCB starts to monitor the signal). This means that the detectors are constantly detecting a
change in reflectivity. The sensors stay activated until the back edge of the plate passes
over the In-feed (On) sensor at which point they then are de-activated (the PCB stops
monitoring the signal). When an Interleaf paper is detected, the sensor must record a
constant signal for more than 20mm of plate travel from either of the detectors. Any period
less than this and the signal will be ignored. If a Interleaf paper is detected, the machine
will stop and a warning will be displayed on the HMI “Interleaf Detected”. The “Jam
Screen” will then displayed so that the plate and paper can be removed. These functions
are available in software 05.01.05 onwards. The Interleaf paper detectors are normally
only used with On-line applications and are therefore not normally required for hand fed
Off-line machines.

Description

There are 2 Keyence FS-V21RP amplifier units fitted to the DIN mounting rail in the
electrical box. Connected to them are the 2 fibre optic cables upper & lower. SW19 is for
the upper sensor and SW20 is for the lower sensor. Please note that the fibre optic cables
should be treated with care as they are easily damaged. Fitting of the fibre optic cable to
the amplifier units is by a cable clamp so do not remove unnecessarily. There should not

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normally be any reason to disassemble the units except for parts replacement. The cable
connection from the amplifier units to the PCB is as follows:

Blue – 0V / Brown - +12V / Black – Signal (High/Low)

Connect the other end of the cable to PL25 on the PCB.

Setting the Sensor Sensitivity

The specifications for the detectors are:

Upper (top) detector – Light On & set to ULtr

Lower (underside) detector – Dark On & set to SuPr

Items a to c are normally only required when the fibre optic cable or amplifier unit is
replaced. Items d to g are required when the interleaf paper density changes or the plate
aluminium surface reflectivity changes. Before re-calibrating the sensors, please ensure
that the fibre optic sensor is clean and free from dust particles. Cleaning may also avoid
the need for re-calibration.

a) To set the Light/Dark option, press the L/D button once. Then use the ÏÐ button to
select the correct option for both units.

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b) To enter the programming menus, press the Mode button for 3 seconds. This allows
entry to the Access Mode Selection Menu. The currently selected option will be
displayed. As a default the units are supplied pre-programmed as “Easy”. If this is
displayed, use the ÍÎ button to select “Full”. This setting allows for the full range
of adjustments and setting to be accessed. This setting is for both amplifier units.

c) To select the correct sensitivity for the amplifier unit, press the Mode button for 3
seconds. The currently selected option will be displayed; this should be “Full”. Press
the Mode button again. This is the Power Mode Selection Menu. The options
available are: FinE/turb/SuPr/ULtr/hSP/rESa. To change this setting, use the ÍÎ
button to select “ULtr” (top sensor) and “SuPr” (lower sensor).

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d) To set the sensitivity of the amplifier units the amplifier unit must know the different
reflective values of the plate coating, substrate and the interleaf paper. For the
upper sensor, place a fully coated plate of the type which is going to be used under
the sensor and press the SET button once. The plate must be flat on the conveyor
as it would be in normal operation. Now place an interleaf paper on top of the plate,
press the SET button one more time.

e) For the lower sensor, place a plate of the type which is going to be used over the
sensor so that the sensor is facing the bare aluminium substrate and press the SET
button once. The plate must be flat on the conveyor as it would be in normal
operation. Now place an interleaf paper under the plate, press the SET button one
more time.

Plate

Interleaf

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f) The amplifier units are now ready to work. The green display is the Pre-set Value
(PV) which was programmed during the calibration process and the red display is
the Current Value (CV) being read by the amplifier unit.

g) Both the interleaf paper detectors now should now be ready to work. If for whatever
reason the detectors need to be de-activated, remove PL25 from the PCB inputs
and the interleaf paper detection will no longer work.

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Page 76 of 116
8.0 - Setting the Developer Section Level Switch

On installation or when the machine is moved and re levelled, the developer section float
switch assembly will need setting. To set, fill the tank up to its highest level with developer
(not water) and let a small amount of liquid overflow. Go to the Engineering section Ä
Test Ä Display IP. Release the locking bolts and push the float switch mounting bracket
to its highest position. The I/O signal reading should be O. Push the float switch mounting
block downwards until the I/O reads I. From this point push the float switch mounting block
1mm further down. Tighten the locking bolts. Place the anti-ox cover into the developer
section and check the I/O still reads I.

Locking Bolts

Float Switch
Mounting
Bracket

Float Switch
Float

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8.1 - In-Feed and Exit Sensor (*) Sensitivity Adjustment

For the Maya to work automatically, the plate must be seen consistently by the in-feed
sensor fitted to the upper in-feed guard. This also applies to the exit sensor jam function so
that it works accurately and consistently

(Plate Material)

To set the in-feed and exit sensor correctly, ensure that it is securely mounted to the In-
feed guard using the lock nuts 2. Make sure that the sensor is not mounted so close to the
plate that it touches the plate surface. Place an un-processed plate under the sensor and
check that it activates. This can be confirmed by the yellow LED built into the sensor or by
using the Inputs list of the Test Menu found in the Engineering section. If the sensor does
not activate, rotate the adjustment screw 1 in the direction of the arrow (clockwise). This
will increase the sensitivity of the sensor. As soon as the sensor is activated rotate the
adjustment screw a further 5° in the direction of the arrow.

(*) Please Note:

On some machines the exit sensor is an option so may not be fitted.

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9.0 - Replacing the PCB

If the PCB needs to be changed the following needs to be done. Before you unplug
anything the settings should be saved in the operator menu. This ensures that the latest
settings have been saved.

It is most important that ESD precautions such as a wrist strap are used before the
PCB is touched.

Remove the board and swap over the fuse holders (if required). If in doubt, please refer to
section 6.3 on fuse positions and ratings. Make sure that the jumpers are in the same
position as the old board (if in doubt please refer to section 6.0, jumper positions and
section 6.2 DIP switch settings). Most boards supplied are Flash Loaded with the correct
software, however if an EPROM is fitted, remove it, also remove IC12 (this is near the
main EPROM) from the old board and fit them to the new board. The EPROM carries the
operating system and IC12 carries the usage data, error log and other history/information
to the new board. Please make a note of process data such as pre-heat temperatures,
developer temperature and replenishment rates just in case this is lost during the data
transfer procedure.

Flash
Chip

IC12
EPROM

If you are not using an EPROM then please refer to the Flash Loader instructions for PC
upgrading of the PCB if it is not already programmed or it requires an upgrade. Once the
board is fitted and all the plugs checked for their correct position, start up the machine.

Please note that for illustrative purposes only the off board transformer version of
the PCB has been shown. For machines fitted with the on board transformer PCB
the process is exactly the same.

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9.1 – Selecting the Machine Identity

If the new board has not been pre-programmed then item 1 to 3 may be displayed.
Regardless of whether the board was pre-programmed or not, item 4 to 9 will always be
displayed. Items 10 & 11 are extra steps that are required.

1) The Select Board Type screen will be displayed. The options are 0247K301 or 0323
C676. To check which board type is fitted please refer to the label affixed between
the PCB transformer connectors (see picture below). The Maya P will always be
fitted with a 0323C676 board. Select 0323C676 and press exit/return to confirm
your selection. The serial number will be affixed to the on board transformer if the
PCB has one fitted.

2) The Confirm Board Identity screen is displayed. Confirm “Yes” if you are sure that
the correct board type has been fitted. Press exit/return to confirm your selection.
3) The Enter Serial Number screen is displayed. Check the serial number of the PCB.
To check the board serial number, please refer to the label affixed to the PCB
between the 2 sockets for the PCB transformer (see picture above) or the label
affixed to the on board transformer if used. Enter the serial number by using the
increase/decrease keys, once the desired number is displayed, press next to allow
entry of the next number. Once this has been completed, select exit/return to
confirm the number. Please note that once this number has been entered it cannot
be amended.
4) The Select Manufacturer screen will be displayed. Select Heights and exit/return to
confirm your selection.
5) The Select Machine Family screen will be displayed. Select Maya and exit/return to
confirm your selection.
6) The option to confirm the machine width is displayed. Choose either the 62 or 85
cm width option.
7) The Time and Date screen will be displayed. Enter the current local time and date.
Select exit/return to confirm and move to the next screen.

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8) The PDI Menu screen will be displayed. PDI stands for Pre Delivery Inspection and
is a factory list for machine checking, setting and calibration. Please scroll to the
bottom of the list (the list is longer than the screen can display). The last entry is
End PDI. Select and confirm by pressing exit/return.
9) Once the End PDI option in the PDI menu has been selected and confirmed by
pressing exit/return, the normal boot up screen will be displayed. Press any key to
start the processor.
10)Go to the Main Menu Ä Engineering (enter the current password using the table in
section 1.0) Ä Service Utilities Ä Settings Ä Calibration MenuÄ Select Read
System Data. This will extract the setting and consumable data information from
IC12 and update the PCB memory. Please note that the operation explained in this
section (section 10) must be carried out within 5 minutes of the board being
powered up for the first time. If it is not the data may be lost as it will be overwritten
after the 5 minutes has expired.
11)After a board change it is always a good idea to check that the correct settings have
been transferred such as the developer temperature, preheat and replenishment
rates.

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9.2 - Clearing the Memory / Self Test Procedure.

When selecting J4 and powering the machine up, the basic memory of the machine is
always reset thus loosing all consumable usage data and processor working parameters.
Therefore if you elect to use the self test utilities explained below, always make a note of
the processing parameters and consumable usage data before fitting the link J4.
From 05.01.00 when selecting J4 and powering up the machine you will be presented with
the following options:

Basic tests – This is as the previous tests, interrogating the RTC, EPROM, PTCal,
EEROM & RAM. The number of passes failed or accumulated at the top of the screen. To
exit, power down the machine to exit the J4 screen, and return J4 to open.

Full board test – This is not to be used as it only works correctly when connected to a test
jig (which is held at S2S). If it is used by accident it will not cause any damage. To exit,
power down the machine to exit the J4 screen, and return J4 to open.

Change board type – This allows for the board type to be changed if the wrong type was
entered into memory by mistake when the board was first programmed. The choices are
0247K301 & 0323C676. Select, then confirm yes or no. Once this is done you are returned
to the J4 options screen. To exit, power down the machine to exit the J4 screen, and
return J4 to open.

9.3 – Advanced Self Test Procedure

It is possible to completely re-set the board. If this is required please contact Heights for
further information.

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10.0 – Upgrading the Software

There are 2 ways to upgrade the software on the PCB. The first is to change the EPROM
and the second is to upgrade using a PC. Both methods are explained below.

10.1 – Upgrading the Software by Exchanging the EPROM

It is most important that ESD precautions such as a wrist strap are used before the
PCB is touched.

Remove the EPROM by means of an appropriate EPROM removal tool being careful to
ensure that the legs of the EPROM are not bent. The EPROMS can be re-used if required.
Slot the replacement EPROM into the vacant socket. Ensure that the notch on the EPROM
matches the notch on the EPROM socket. Check that all the EPROM feet are located into
the socket and push gently but firmly until the feet are fully secured into the socket. Please
refer to section 10.2 for information on software selection options.

10.2 – Upgrading the Software by Using the Flash Loader Programme

The Flash Loaded is a dedicated programme used to load the operating system onto the
PCB from a PC. It is downloadable from the Heights Support Zone with the appropriate
password and user name. Initially a kit will need to be ordered and this can be obtained
from Heights UK Spare Parts Dept using the part number 0323K678. The kit includes a
dedicated download cable needed for connecting the PC to the PCB (0323E677). A serial
to USB adaptor (7279-209) for connecting the serial download cable to a USB port, printed
instructions (0323M695) and a CD containing the latest software (0323B696). The Flash
Loader software is written to only work on PC’s using Windows 95/98/ME/XP.
To load the software onto a PC for the first time, ensure that the file extension of the FI file
is .exe. The FI file is the Flash Installer programme. There is also an FU file which is the
Flash Upgrade programme. The files that are downloaded from the Heights website use
the file extension .exx. This is so the programme can be sent by e-mail and not filtered out
as a potential virus. An example of a full file name is FI_03_00_09.exe. Double click on the
FI file icon and agree to the licence agreement.

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By default the software is automatically loaded into the file C:\HFL\ (HFL stands for heights
Flash Loader). The programme files go into C:\HFL\programms and the documentation
goes into C:\HFL\docs\.

When the programme is loaded a shortcut is added to the start menu and to the desktop.
Included in the start menu shortcut is the option to uninstall the programme.

To upgrade the version of software that is resident in the Flash Loader programme
installed on your computer. The FU file needs to be used. Again, ensure that the file
extension is .exe. Double click on the FU file icon and the programme will install the
necessary update files.
Once the Flash Loader programme is installed to your PC, the PCB needs to be prepared
to receive the new software. Turn the processor off at the main isolator. Open the panel
door and connect the serial download cable to PL4 on the board.

PL4

Connect the other end of the serial download cable to a spare 9 pin serial cable port on the
PC with the Flash Loader programme installed. If there is no serial port available (as is the

Page 84 of 116
case with many modern laptop computers) use the supplied RS232~USB adaptor. Ensure
that J2 is linked to pin 2&3 (flash). J5 is linked across pins 1&2 (bootstrap loader
condition). J6 is linked to pins 2&3 (RS232 selected). Now the processor can be powered
up.

J5
J2

J6

When the processor is powered up, you will notice that the HMI is blank. This is correct
while the processor PCB is in Bootstrap mode. Double click the Flash Loader icon on the
PC to start the programme. If it is the first time the programme has been used it will need
to be configured. On starting the Flash Loader programme needs to scan for available
COM ports. You will be asked to confirm this by selecting Return to continue.

The next stage is to confirm the COM port selected. If you are using a serial port than this
will always be the port you use, so save the selected port by typing Y & Return. If you are
using a USB port it may be better not to save the port as there are normally more than 1
USB ports available on a PC. Type N & Return. If you save the USB port, ensure you use
the same port each time you plug the download cable in to the PC.

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The programme will now erase the existing Flash programme data on the PCB. The
progress will be displayed in seconds in the dialogue box. The Flash Loader programme
will then automatically download the new version of software to the PCB flash memory.
Again the progress of the download will be displayed in seconds in the dialogue box.
Depending on the speed of the computer this could take anything up to 5 minutes to
complete. Once this has finished, hit Return to exit the Flash Loader programme.

To complete the process, isolate the processor from the mains. Remove J5 from the
Bootstrap Loader position and power the machine back up again. Depending on the type
of upgrade loaded into the processor PCB it may be necessary to refer back to section
10.2 and follow the board configuration process.

Page 86 of 116
10.3 – Flash Loader Trouble Shooting

If the following dialogue box is displayed:

There are a number of potential causes. This normally only happens when using a
USB/Serial adapter. The following lists options for adjustments using Windows.

A - Close down Heights Flash Loader program. Power down the machine PCB and check
that J5 is in the “Bootstrap” position, J6 is in the “RS232” position and that J2 is in the
“Flash” position. Power the machine back up again and re-start the programming
procedure.
B - Close down all applications on the PC and “Restart”. Power down the machine and
then power the machine back up again and re-start the programming procedure.
C - Check the COM port allocated to the down load cable. This normally only applies to a
download cable using a USB port. Select “System” from the “Control Panel”.

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Select “Device Manager”.

Open up the “Ports” option to see what COM port allocation has been made. The Heights
Flash Loader only scans ports 1 to 8, so if the allocated COM port is greater than 8 it won’t
be recognised. Try moving the download cable USB plug to a COM port from between 1
and 8. Close all dialogue boxes and re-start the programming procedure.

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D - Go to the “COM Ports” displayed in the “Device Manager. Right click on the COM port
in use. Select “Properties”. Then select “Port Settings”

Change the “Bits Per Second” value to that which is seen on the Heights Flash Loader
dialogue box. Changing from 9600 to 38400 may have an effect

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Close all dialogue boxes and re-start the programming procedure.

E - Ensure that the driver for the Serial/USB converter has been installed correctly. Re-
install if required

F - Try a different make of Serial/ USB converter. One with a Prolific chip in it is preferable.

G - Re-assign the COM port number if you are unable to find a suitable COM port
displayed. Go to the “Port Settings”. Select the “Advanced” option.

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Select the drop down menu “COM Port Number” from the “Advanced Settings for COM X
(where X is your currently assigned COM port number) and select a COM port that is
between 1 and 8. Select “OK and exit all screens.

H – Always remember to reset (power down and re-start) the PCB when re-trying to
programme the PCB. Without re-setting the PCB the PC will not recognise the PCB target
and will display “Unable to Find Connected Hardware” as shown below..

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Page 92 of 116
11.0 – Plate Setter Interface

There are 2 types of setter interface available for the Maya 85T processor. The first is a
unidirectional interface that can be programmed (via the HMI on the processor) to output a
2 bit signal. This signal can send 4 different states to a plate setter by switching 2 voltage
free relays. This is used by Plate Setters that send their own signal for the processor to
switch. The second is a bidirectional interface which is also programmable via the HMI on
the processor however factory instructions are required for this. An instruction sheet for
each Plate Setter is available from Heights UK. The interface can output a 4 bit signal to
the plate setter indicating machine status but it can also receive a 4 bit data signal from the
plate setter. This is used by plate setters that require an opto-isolated 5~12 VDC signal
generated by the processor.

Unidirectional interface

The unidirectional interface assembly (below right) has a PCB 0285P131A (below left)
fitted inside it. The whole assembly is mounted on the DIN rail inside the main electrical
enclosure.
0285P131A

PL2 PL1

RL1 RL2 RL3

PL3 PL4 PL5

Page 93 of 116
Part Numbers

Part Number Description Where Used

0285K147 PCB Interface Box Spare part
PCB Interface Kit (includes PCB
0285B220 Complete fitting kit
cable only)

Connections

The input connections PL1 & PL2 are connected to the main PCB at PL1 (just above the
D-Sub 9 pin serial connection for the LCD screen) and PL37 (just below the D-Sub 9 pin
serial connection for the LCD screen). The output connections PL3, 4 & 5 are for the 3
sets of voltage free contacts (relays). These relays switch the output signals from the plate
setter. Each relay has 1 set of NO contacts and 1 set of NC contacts (please refer to
drawing 0231E082). The relevant connections are shown below

Relay Number PL Connector Status

RL1 PL3 Programmable
RL2 PL4 Programmable
RL3 PL5 Power On/Off

The choice of using either the NO or NC set of contacts is dependant on the application
and type of machine that the interface is to be used with.

Programming the interface from the LCD screen

The interface can be programmed using a programming screen in the software. To get to
this screen go to Engineering Menu Î Settings Î Plate Setter Menu Î Configure User
Setter. The screen is shown below;

Configure User Setter

1 Exit 2

3 Next 4
Level Level RL1 RL2

Fault 0 1
5 Relay 1 N Rdy 0 1 6
Busy 0 1
Ready 1 0
7 Relay 2 8

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Using the button “Next Level” moves the cursor down through the list - FAULT, N RDY,
BUSY & READY. When one of the levels is selected, press the Relay 1 or Relay 2 button
to change the relay state to 1 (on) or 0 (off). In the example shown above, the ready signal
is being switched by RL1, so when the processor is ready RL1 will be switched on and
RL2 will be switched off. RL2 switches the not ready signal, so all signals from the
processor which indicates that it is not ready to process a plate turns RL2 on and RL1 off.
RL3 is not programmable and is always energised when the power is turned on. When
using the Configure User Setter, the Select Setter I/F menu must have Configure User
Setter selected (see below).

Selecting the user interface

The user interface type can be selected by using the Select Setter I/F. To get to this
screen go to Engineering Menu Î Settings Î Plate Setter Menu Î Select Setter I/F. On
this screen there are a number of plate setter options. Go into the Select Setter I/F menu
and select Configure User Setter otherwise the interface will not operate. Then enter the
required data into the programme interface screen as described in section 12.4.

Changing error levels

This should not normally require changing as the default setting works for most plate
setters. Level 1 = Fault. Level 2 = Not Ready. Level 3 = Warning. No level (blank) = No
action. If you think they need changing, please seek assistance from Heights UK.

Testing the interface

To test the interface relays, enter the Engineering Menu Î Test Î Setter I/F Test. This
screen allows the selection of the following;

Test Number Action

0 Error/Fault
1 N RDY (not ready)
2 Warning/Busy
3 Ready

Depending on how the interface has been programmed (see programming the interface
from the LCD screen & selecting a pre-programmed interface) the switching of the relays
will be different. For example, select test number 3. Using the programming shown in the
illustration previously in item 5, the relay RL1 will be energised and the relay RL2 will not
be energised.

Page 95 of 116
 This page
intentionally left
blank

Page 96 of 116
11.1 - Mini Chiller

Setting the temperature limits

Engineering Menu Î Settings Menu Î Temperature Limits Menu Î Dev Temp Limits.
In this menu you can set the upper limit and the lower limit. Normally this is set to +/- 2 deg
C violet Ctp plates. When the temperature exceeds the upper or lower limits set the
processor will not accept plates. A Not Ready signal will be generated and if the processor
is connected to an interface, the interface will send the Not Ready signal to the Plate
setter. This can be adjusted in increments of 0.1 deg C to a maximum of +/- 10 deg C.

Disabling the temperature limits

Engineering Menu Î Settings Menu Î Temperature Limits Menu Î Disable Temp

Limits. Select “Disable” to turn off the temperature limits. This means that a plate will be
accepted even if the developer temperature is wrong. When the machine is turned off
electrically (not put into sleep mode) the temperature limits will automatically be re-
enabled.

How the temperature control works

When the developer is 0.2 deg C greater than the set point the microprocessor on the PCB
sends a signal to turn on the chiller circulation pump. The water in the chiller is
automatically kept at a constant temperature (pre-set by the temperature controller built
into the chiller). The PT 100 probe in the developer tank sends the temperature data to the
PCB. The connection to the PCB for the PT100 probe is PL5. When the temperature has
dropped by 0.2 deg C the microprocessor on the PCB sends a signal to turn off the chiller
circulation pump. The water is constantly chiller regardless of demand.

The temperature controller fitted to the mini chiller

The LED temperature controller on the side of the chiller assembly does NOT control the
temperature of the developer. It controls the temperature of the WATER in the chiller. The
temperature displayed on this controller is the temperature of the water in the holding tank
built into the chiller assembly. Pressing the “prg” (3) button for a couple of seconds will
display the set value for the water. This should normally be 10 deg C. This is the
temperature that the temperature controller keeps the water at all times. It is normal for the
temperature of the water to increase as the chiller pumps cool water through the cooling
trombone in the developer section.

CAREL PJ32V6P0000 CONTROL

1. set1 - set-point1 selector button

2. set2 - set-point2 selector button
3. prg - temperature value display
4. Temperature/set-point value display

Power supply to the chiller

Page 97 of 116
The power supply to the chiller comes from CB4. The compressor runs automatically to
ensure that the water inside the chiller is kept at the programmed temperature all the time.
When there is demand for cooling, RL3 on the PCB will activate. This turns on the chiller
circulation pump and pumps the water through the single cooling trombone in the
developer section. There is a yellow LED just below the relay that shows when it has been
energised.

Faults on the chiller assembly

The chiller assembly has a number of safety functions built into it. If the chiller assembly is
completely inoperable with no LED readout then check the supply from CB4. To ensure
that the chiller has sufficient water in the holding tank, there is a level switch. When the
water level is low the large red light is illuminated next to the temperature controller. The
pump turns off and the chiller will not function. Fill the tank up and the chiller will
automatically re start. There is also a high pressure switch for the coolant. If the pressure
rises due to a blockage, the chiller will turn off. If any of these faults occur, the Maya
processor will still function. Only the developer temperature will rise. In this case,
temporarily change the temperature Limits to allow for a greater rise in temperature until
the chiller can be repaired or replaced.

Fault finding on the temperature controller

Display Error Description & Remedy

E0 PROBE 1 FAULT = REPLACE PROBE
E1 PROBE 1 FAULT = REPLACE PROBE
IA IMMEDIATE EXTERNAL ALARM (NOT USED)
LO LOW TEMPERATURE ALARM (NOT USED)
HI HIGH TEMPERATURE ALARM (NOT USED)
DATA ACQUISITION FAILURE = THE CONTROL SHOULD RESET
EE ITSELF INDICATED BY FLASHING EE THEN --- ALTERNATIVELY , IF
CONTROL DISPLAYS EE CONSTANTLY , REPLACE CONTROL .

Page 98 of 116
11.2 – Mini Chiller Planned Maintenance Schedule

External checks and inspection for signs of deterioration.

• Control Panels
• Fixing Fasteners
• Isolators
• Guards
• Labelling etc

Check water/fluid levels and top-up where necessary

Check for undue noise and vibration

NOTE

All safety devices and controls should be checked during routine maintenance and
adjustments made if necessary.

The following table illustrates a recommended planned maintenance schedule along with
desired frequency. There are items which may not always be fitted.
These are for guideline purposes and will need to be re-evaluated if the chiller is running in
a contaminated atmosphere or has extreme or long operating conditions etc.

External inspection for signs of general deterioration i.e

CHILLER - GENERAL Yearly
holding down fasteners, labels, tagging etc
Check operation of evaporator trace heating and control
* Half Yearly
thermostat
Remove all control panel covers, inspect all mechanical
* Yearly
and electrical components
* Check condition of water tank Yearly

* Check condition of water tank insulation Yearly

Inspect condenser coil and clean where necessary using
CONDENSERS Half Yearly
compressed air (2 bar max) and soft brush
* Check fan speed controller settings and calibrate if required Yearly

* Check operation of fan motor and record currents Yearly

Carry out earth insulation test on motor windings and
COMPRESSORS Yearly
record
Connect system gauges to compressor(s), record
* discharge and suction temperatures, pressures and hours Half Yearly
run
Check oil temperatures and pressure throughout
* Half Yearly
compressor body during operation

Page 99 of 116
 * Check noise and vibration Quarterly
Check compressor starting running currents, supply
* Yearly
voltages and record
Check operation and condition of thermostatic expansion
REFRIGERANT CIRCUIT Yearly
valves, record superheat conditions
* Check system for refrigerant leaks Half Yearly

* Check refrigerant charge Half Yearly

Check operation of all low and high pressure safety cut
* Half Yearly
outs
Check operation of all discharge pressure controls where
* Half Yearly
applicable
* Check operation of oil pressure controls safety’s Half Yearly
Check operation and condition of all printed circuit boards,
* Yearly
time guard circuits and over ride delays
CHILLED WATER
Check wiring and starters Yearly
PUMP(S)
Check all cable terminations, re-terminate and tighten if
* Yearly
required
* Check for moisture in electrical compartments Yearly
Check operation and condition of all controls, relays and
* Yearly
electrical starters
* Check for fluid leaks Half Yearly

* Check operation of fluid pumps Half Yearly

Remove flash guards/covers from compressors starter
* Yearly
assemblies and inspect contacts

Page 100 of 116

11.2 – Functional Explanation of the Pre-Heat

The Maya 62P & 85P use ceramic heater tiles that work in the long wave Infra-red wave
length. This is the same technology that is used in the pre-heat box of the Heights
manufactured photopolymer processors. The output temperatures from the ceramic
heater blocks are controlled by the PCB software using temperature data sent from 3 of
the ceramic heater blocks which have K-type thermocouples embedded inside them. Too
ensure the highest quality of pre-bake the PCB software has to have temperature setting
data entered for different thickness plates (0.15/0.20/0.24/0.30).

How the pre-heat box is wired & controlled.

The pre-heat box for the Maya 62P has 5 ceramic tiles connected as shown below.

Outer Left Outer Right

Inner
The pre-heat box for the Maya 85P has 7 ceramic tiles connected as shown below.

Outer Left Outer Right

Inner
The blue lines represent the wiring connections and the green circles the K-type
thermocouples. From this you can see that pre-heat box is split into 3 zones, outer left,
outer right and inner. The 2 outer zones are independently controlled by tiles fitted with
thermocouples. The inner zone consists of 3 tiles connected together, 1 of which has a
thermocouple fitted. All 3 thermocouples input temperature data from the heating element
inside the tile back to the PCB. This data from the thermocouples is displayed on the LCD
screen of the Maya as the “Outer Left Temp/Inner Temp/Outer Right Temp”. This
temperature represents the inner core temperature of the tile only, not the air or plate
temperature. The temperature is controlled by the PCB software. This is done by “pulsing”
the power supply through a solid state relay.

Page 101 of 116

Pre-heat specifications

The Maya pre-heat is specifically designed to work with offset lithographic plates which
require fast heating over a very short duration. The accepted speed for these plates and
the Maya pre-heat is at present between 1000 and 1300 mm per min depending on the
chemistry used. Please refer to the plate manufacturers data for accurate setting of the
conveyor speed. The temperature window which the different plate manufacturers systems
work to is generally between 94~116 deg C. The temperature tolerance band anywhere on
the plate that the Maya can control is +/- 1 step on a temperature strip. Although the
machines leave Heights calibrated, this is only a basic setting and an installation
check/adjustment must be made so that the correct temperatures are entered into the
software for the customer’s requirements on each plate thickness. Once this is done it
should not normally need to be adjusted except when there is a component change to the
system.

Productivity

The Maya pre-heat system requires a short period of time to stabilise after each plate. This
ensures the best possible pre-heat temperature consistency. The programming for the
machine as it leaves Heights allows for a 30~35 second gap between plates.

Soak times

These are the times which can be entered into the PCB software to ensure that the pre-
heat temperatures have stabilised when the machine is first turned on or when the
machine is stopped and re-started. The Maya is delivered with no soak values entered into
the software. It is up to the plate technician to decide if it is appropriate for the customer to
have these values entered. If you wish the Maya processor to have these values entered
into the software, go to Engineering MenuÎ Service UtilitiesÎ SettingsÎ Temperature
LimitsÎ Pre-Heat Soak De-BugÎ Enter the times that the machine will be stabilising
next to the off time segments. The soak time means the period of time it takes for the
whole machine to warm up, not just the pre-heat. Once all the metalwork around the pre-
heat has warmed up then the temperature in the pre-heat will be stabilised to the correct
level. It is generally accepted that the Maya pre-heat requires about 20~30 mins to
stabilise from a cold start. After this the machine is ready to go into full production
(providing the developer is at the correct temperature). If a plate is made immediately the
ceramic tiles come up to temperature (<5 mins) without allowing for the correct soak time,
the first plates may have a temperature inconsistency.

Extra features of the control system

To help further control the temperature on the plate there is a setting to help keep the back
edge of the plate cool. Normally, when running at about 1 meter per min the heat from the
pre-heat box travels along the plate quicker than the plate travels into the machine. This
means that there is a very high likelihood of the back edge of the plate being hotter that
the rest of the plate. To help control this, there is the ability in the PCB software to
automatically turn off the pre-heat as the back edge of the plate enters the pre-heat. This
is known as the “Set Back” and is activated in the software when the machine leaves
Heights. This is found in the pre-heat temperature settings.

Page 102 of 116

11.4 – Carrying Out a Pre-Heat Temperature Test

To ensure the correct processing and run length from the plate, the pre-heat temperature
has to be accurately set for each plate thickness used. To do this, test plates need to be
produced which measure the temperature of the plate as it passes through the pre-heat
box. From this the correct pre-heat box temperatures can be programmed. For the correct
temperature range needed, please use the data supplied from the plate manufacturer or
suppler.

What is required for the test?

You will need samples of each plate thickness/gauge that the processor will use. These
sample plates must be unused as the pre-heat test must be carried out with the PVA
coating. You will also need some temperature strips. There are many different suppliers of
temperature strips. These should be scale B and preferably 10 steps. Please choose one
that measures the temperature to at least 116 deg C (241 deg F). A supplier of reliable
temperature strips is:

UK & Europe
Thermographic Measurements Co. Ltd
Riverside Buildings, Unit 1 Dock Road, Connah's Quay, Flintshire, CH5 4DS UK
Telephone: +44 (0) 1244 818348 Fax:+44 (0) 1244 818502
E-Mail: [email protected] http://www.t-m-c.com

US & C
Thermographic Measurements
1820 Pickwick Lane, Glenview, IL 60025 USA
Toll Free: +1 877-887-8367 Fax: +1 847-998-6866
E-Mail: [email protected] http://www.t-m-c.com

Heights can supply the Thermax 10 level strip; p/n-7668-877 (per pack).

Pre-heat temperature calibration

Ensure that all the covers are fitted to the machine. This is important as it provides the
normal operating environment for the test. Check that the conveyor speed is correctly set
to the plate manufacturer’s recommendation. Select the plate thickness (gauge) from the
top right hand corner of the normal operating screen on the HMI. If the machine is “On-
Line”, select “Off Line” and manually select the test plate gauge. Allow the machine to
soak (temperature stabilisation time) for about 10 mins.
Select the biggest plate of the thickness (gauge) to be tested. Turn the plate over on a flat
surface and affix the temperature stickers to the back side of the plate. The drawing on the
next page will help you to select which positions and how many strips to use. When
applying the stickers to the plate make sure that they are fully stuck to the aluminium.
Firmly push down with your thumb over the full area of the sticker.

Ensure that the test plates and stickers are stored away from temperatures above or
below the room’s ambient temperature before the test is carried out.

Enter the plate into the processor in the direction that it would normally enter the machine.
Allow the plate to complete the full processing cycle. Inspect the temperature stickers and
record the maximum values on the back of the plate. From these values the pre-heat

Page 103 of 116

temperature zones can be increased or decreased. It is suggested that a modification in
temperature to each zone should be limited to no more than 5 deg C in one adjustment.

Temperature strip position options

Plate
direction
of travel

25mm
(1”)

25mm
(1”)

Basic Advanced Full test

temperature
strip positions
+ temperature
strip positions
+ temperature
strip positions

This example of a
used temperature strip
shows an indicated
temperature of 110
deg C/230 deg F. If the
next segment turns
>30% darker, this
indicates that the next
temperature has been
reached.

To modify the pre-heat zone temperature values, go to the Engineering MenuÎ Process
Settings Î Pre-Heat Menu ÎSelect Plate Thickness/Gauge being tested. Enter the new
values as required to the Pre-Heat Left/Inner/Right. Do not change the Set Back Value.
Exit until you are offered the option to save settings. If you are happy with the values
entered, confirm by pressing Continue and exit the Engineering Menu.
Allow the pre-heat to stabilise for a further 10 minutes and repeat the test. Adjust if
required. Once you are happy with the results go on to test any other plate
thicknesses/gauges that are used in exactly the same way as previously described.

Page 104 of 116

12.0 - General fault finding

Incorrect developer
Check the replenisher
replenisher rate (too
setting and operation
high)

Check temperature
setting & displayed
temperature (refer to
plate manufacturer for
recommended
temperature)
Check actual
developer temperature
Developer
Check developer flow
temperature too high
Check developer filter
and housing
Check heater
operation and SSR
Calibrate PT100 input
on PCB
Check operation of
chiller

Dot shrinkage
Check the plate dip to
nip time (refer to plate
Highlights disappear
manufacturer for
Platemaking
recommended time)
Check motor
Development time to
Check roller drive
long
system
Check roller nip
pressure
Check encoder step
and feed back

Check settings and

temperature on display
Check plate
temperature with
temperature strips
Pre-heat temperature (refer to plate
too low manufacturer for
recommended
temperature)
Check heater tiles and
wiring
Check SSR’s

Page 105 of 116

 Check PH
Check if water is
entering the developer
section from the pre-
Incorrect developer
wash or rinse sections
dilution
Check for blocked
drainage or kinked
pipes in the pre-wash
or rinse sections

Check the
replenishment setting
Incorrect developer
Check operation of
replenishment
pump
Calibrate pump

Check PH
Exhausted developer
Replace developer

Dot gain
Check temperature
Shadows fill in setting & displayed
temperature (refer to
Residual emulsion in plate manufacturer for
recommended
Platemaking non image area
temperature)
Check actual
Developer
developer temperature
temperature too low
Check developer flow
Check developer filter
and housing
Check heater
operation and SSR
Calibrate PT100 input
on PCB

Check water supply is

turned on and the
pressure is constant
Check and clean spray
bars
Insufficient rinse
Set spray bar output
Check filters (for
recirculation only)
Check solenoid valve
(direct to drain only)

Page 106 of 116

 Check and set
developer brush
pressures
Incorrect developer
Check condition of
brush pressure
brushes
Check condition of
bearings and bushes
Dot gain
Check settings and
Shadows fill in
temperature on display
Check plate
Residual emulsion in
temperature with
non image area
temperature strips
Incorrect pre-heat (refer to plate
temperature manufacturer for
recommended
temperature)
Check heater tiles and
wiring
Check SSR’s

Check and set

developer brush
Incorrect or uneven pressures
developer brush Check condition of
Platemaking pressure brushes
Check condition of
bearings and bushes

Check settings and

temperature on display
Check plate
Non-uniform tints & temperature with
screens temperature strips
Uneven temperature in (refer to plate
Lines in tints & the pre-heat section manufacturer for
screens recommended
temperature)
Check heater tiles and
wiring
Check SSR’s

Dirty rubber pre-heat Clean each wheel so

exit wheels that no PVA is left

Check PH
Developer is too weak
Replace developer

Page 107 of 116

 Check and set
developer brush
Incorrect or uneven pressures
developer brush Check condition of
pressure brushes
Check condition of
bearings and bushes

Check temperature
setting & displayed
temperature (refer to
plate manufacturer for
recommended
temperature)
Check actual
developer temperature
Developer
Check developer flow
temperature too high
Check developer filter
and housing
Check heater
operation and SSR
Calibrate PT100 input
on PCB
Check operation of
chiller
Scratches or pin
holes in image area
Platemaking
Check the plate dip to
nip time (refer to plate
manufacturer for
recommended time)
Check motor
Development time too
Check roller drive
long
system
Check roller nip
pressure
Check encoder step
and feed back

Check settings and

temperature on display
Check plate
temperature with
temperature strips
Pre-heat temperature (refer to plate
too low manufacturer for
recommended
temperature)
Check heater tiles and
wiring
Check SSR’s

Page 108 of 116

 Check the condition of
the wheels in drier
section
Plate output is
Clean all gum from
incorrect
wheels
Check the wheels are
free running

Scratches or pin
holes in image area Ensure the pre-wash
splash cover is fitted
correctly
Check the first spray
Pre-wash is splashing
bar is directed into the
back towards pre-heat
scrub roller
Set the spray bar
pressure to eliminate
splashing or dripping

Clean the processor &

Developer processing fill with new developer
capacity exceeded Change developer
filter

Contaminated rinse Drain & clean tank

Platemaking
water (recirculation Replace filter & re-fill
only) with fresh water

Check settings and

temperature on display
Check plate
temperature with
temperature strips
Blue/green scum or
Pre-heat temperature (refer to plate
sludge build up in
too high. manufacturer for
developer section
recommended
temperature)
Check heater tiles and
wiring
Check SSR’s

Check water supply is

turned on and the
pressure is constant
Low water pressure or
Check and clean spray
incorrect brush
bars
pressure in the pre-
Set spray bar output
wash section
Check filters (for
recirculation only)

Page 109 of 116

 Check water solenoid
(for direct to drain
only)
Check the first spray
Blue/green scum or Low water pressure or
bar is directed into the
sludge build up in incorrect brush
Platemaking scrub roller
developer section pressure in the pre-
Check brush condition
(cont) wash section (cont)
Check & set brush
pressure
Check bearing block
condition

Check PH
Check the
Incorrect developer replenishment setting
replenishment Check operation of
pump
Calibrate pump

Clean the processor &

Developer processing fill with new developer
capacity exceeded Change developer
filter

Check temperature
setting & displayed
temperature (refer to
plate manufacturer for
Scrumming of non- recommended
image area temperature)
Printing Check actual
Developer
Shadow area filling developer temperature
temperature too low
in Check developer flow
Check developer filter
and housing
Check heater
operation and SSR
Calibrate PT100 input
on PCB

Check water supply is

turned on and the
pressure is constant
Check and clean spray
bars
Insufficient rinse
Set spray bar output
Check filters (for
recirculation only)
Check solenoid valve
(direct to drain only)

Page 110 of 116

 Check PH
Check the
Incorrect developer
replenishment setting
replenishment (too
Check operation of
high)
pump
Calibrate pump

Check temperature
setting & displayed
temperature (refer to
plate manufacturer for
recommended
temperature)
Check actual
Developer developer temperature
temperature too high Check developer flow
Check developer filter
and housing
Check heater
operation and SSR
Calibrate PT100 input
on PCB
Check chiller operation
Dot sharpening

Printing Reduced run length Check the plate dip to

nip time (refer to plate
manufacturer for
recommended time)
Check motor
Developer time too
Check roller drive
long
system
Check roller nip
pressure
Check encoder step
and feed back

Check settings and

temperature on display
Check plate
temperature with
temperature strips
Pre-heat temperature (refer to plate
too low manufacturer for
recommended
temperature)
Check heater tiles and
wiring
Check SSR’s

Scratched or Grit or dirt lodged in

General
damaged plates brush roller bristles Clean brush rollers

Page 111 of 116

 Replace brush rollers

Damaged brush roller

Replace brush rollers
bristles

Dirty or damaged
Clean rollers
rubber surface of
Replace rollers
conveyor drive rollers

Check the condition of

the wheels in drier
section
Dirty exit wheels Clean all gum from
wheels
Check the wheels are
free running

Excessive pre-wash Set pre-wash brush

brush pressure pressure

Set developer brush

roller pressure in
Excessive developer
accordance to the
brush pressure
plate manufacturers
specification

Check condition of
Plate not feeding conveyor rubber
through machine rollers
Insufficient conveyor
correctly Set conveyor rubber
roller pressure
roller pressures
Check roller mounting
blocks/bearings

Hand feed a plate

through the machine
using the Service Key
Incorrect plate path Menu
Check all components
have been replaced in
the machine correctly

Check roller mounting

bushes
Inconsistent Damaged gum
Clean roller with hot
finishing/gumming applicator roller
water
Replace roller

Inconsistent
Hardened finisher/gum
General finishing/gumming Clean all rollers with
deposits on rollers
(cont) hot water

Page 112 of 116

 Damaged finisher/gum
Replace
rollers

Empty finisher/gum
Replace with full bottle
bottle
Drain finisher/gum
Clean section with hot
water
Clean all rollers with
Contaminated finisher
hot water
Refill with fresh
finisher/gum

If too high, add water

to correct viscosity
(SG). Refer to
Finisher/gum viscosity
manufacturers
to high or too low
recommendations
If too low, replace with
fresh finisher/gum

Circuit breaker tripped Check for fault

in electrical box Reset circuit breaker

Reset emergency stop

switch
Check emergency
Emergency stop circuit stop circuit
activated Check interlock switch
and actuator setting
Check pre-heat over
temperature cut out
Machine will not
process a plate when
power is on (display
Check and set in-feed
working) Sensor fault
sensor

Faulty main isolator Replace isolator

Check all 3 phases are

Faulty power supply
working correctly

Faulty developer level Set sensor

sensor Replace sensor

Page 113 of 116

 Notes

Page 114 of 116

 Notes

Page 115 of 116

 <E
Page 116 of 116