Product

• Lotem™ 800 (S-speed)
• Lotem™ 800 (F-speed)
• Lotem™ 800 Quantum
• Lotem™ 800 with Spectrum

Error

'Vacuum did not grab the plate'

Symptoms

During the first stage of loading, the machine does not pick the plate up from the cassette.

Solution

This section includes a detailed troubleshooting procedure. If at any point you feel that you have found the source of the problem, you can either process several plates to verify that the problem has been resolved, or you can continue to the end of the procedure.

1. Keep the plates that were not successfully picked up from the cassette.
2. Review all generic troubleshooting questions with the customer.
3. Verify whether the customer's machine is a Local 2 machine. If it is, verify whether:
   1. Software patch #3 has been installed and
   2. FCO 28061 has been performed.

   If they have not been:

   • Install software patch #3 and perform FCO 28061.

4. Inspect both the following elements of both the Y and X motor assemblies:
   1. Belt. Use a jig (p/n 507A3E593) to check the belt tension. If the tension is not acceptable, adjust the Y motor belt tension, as required.
   2. Motor Housing securing screws. Use a screwdriver to verify whether the screws are tightly secured. If they are not, tighten the motor housing securing screws.
   3. Motor Shaft Ball Bearing. Closely inspect the motor casing around the area of the shaft (shown below—use a magnifying glass, as required). Look for:
      • Damage of any kind.
      • Protruding springs.
      • Small, metal balls stuck on the outside of the motor.

      

      If any of these are found, replace the Y motor assembly.

   4. Repeat steps 4a through 4c for the X motor assembly.
5. Verify that the plates currently being used are correctly defined. If they are not, modify the plate definition or create a new plate definition, as described in the user manual, and perform plate loading. If the problem persists, proceed to the next step.
6. Inspect the plate(s). Look for damage, defects or warping. This may indicate manufacturer’s defect, or damage that was caused to the plate either during handling or due to bad storage conditions, such as extreme hot or cold. If defect or damage is found, load new, undamaged plates, and then perform plate loading. If the problem persists, proceed to the next step.

   Note: If conditions in the plate storage room do not meet product guidelines, consult your plate supplier for advice.

7. Visually inspect the inside of the cassette. Verify that:
   1. There are no foreign objects such as cardboard, packing material or debris in the cassette. If there are, remove the foreign objects and perform cassette loading.
      Note: If this is a recurring problem, answer all generic troubleshooting questions and then, contact your service representative.seal the cassette by installing a cassette seal cover (p/n 510P1P231). In addition, install the cassette seal cover holder by performing FCO 27885.
   2. The plates are properly loaded and positioned in the cassette. If they are not, reload undamaged plates into the cassette and perform plate loading.
8. Use a spirit level to verify that the machine is properly leveled. If it is not, answer all generic troubleshooting questions and then, contact your service representative.perform machine leveling.
9. Inspect the XY bar suction cups for:
1. Damage of any kind. If found, answer all generic troubleshooting questions and then, contact your service representative.replace the damaged XY bar suction cup(s).
   Note: Verify that the correct number of spacers are installed for each suction cup.
2. Debris and/or dirt. If found, clean the XY bar suction cups using a clean, lint-free cloth.
   Note: This indicates that preventive maintenance is not being properly and/or regularly performed.
10. Inspect the bar flag and verify whether it moves up and down freely. If it does not, answer all generic troubleshooting questions and then, contact your service representative.:
• Remove the XY bar cover and inspect the bar flag and bar flag detector for debris, dirt and/or other obstruction. If found, clean the bar flag and the inside of the bar flag housing, and remove any debris or obstruction, as required. Use a Q-Tip to thoroughly clean the detector. Make sure that no pieces of cotton are left on the lens after cleaning. If the problem persists:
• Replace the bar flag according to the new bar flag and housing FCO.
11. Verify that the bar flag detector is functioning properly. If it is not:
    • Run the Lotem 800 Diagnostic Software (select Machine> Bar Flag Detector). If the result is fail, with the XY bar upper cover removed, visually inspect the bar flag detector wiring and verify that it is properly attached. If it is not:
    • Attach, repair and/or replace the wiring, as required, and repeat step 10. If the problem persists:
    • Replace the bar flag detector.
12. Verify that the XY bar does not hit the cassette plate guides during loading. If it does:
    • Raise the level of the plates in the cassette by placing several used plates covered by a piece of cardboard in the bottom of the cassette, and then placing the plates on top of the cardboard. Then:
    • Perform plate loading. If the problem persists, or if this is good only as a temporary solution, answer all generic troubleshooting questions and then, contact your service representative.install GTO plate guides and instruct the customer regarding when and how to use them.

      Note: Ensure that the XY bar suction cups do not hit the GTO plate guides during loading.

13. Verify that the loading system is properly aligned, as follows:
1. Check XY parallelism.
2. Verify that the XY bar is level.

If either component is not properly aligned, answer all generic troubleshooting questions and then, contact your service representative.align the loading system.

14. Close all doors and perform plate loading using undamaged plates (inspect the plates before loading them into the cassette). Also, verify that they are not too cold to use due to poor storage conditions. If the problem persists, answer all generic troubleshooting questions and then, contact your service representative.
15. Insert the open cassette into the machine, leave the front door open and, using a cheater, perform plate loading.

    Note: If the customer is using a dual cassette, be sure to redefine the cassette as dual loading before leaving the site.

16. Watch the plate as it is loaded and verify whether it hits, or is hit by, any machine parts as it progresses. If it does, adjust the values for the following parameters, as required:
    • Utilities>Hardware\Loading System\Loading System\Loading System Setup "X Position In Cassette (mm)
    • Utilities>Hardware\Loading System\Loading System\Loading System Setup "Prepare Y to catch Plate (mm)
    • Utilities>Hardware\Loading System\Loading System\ "X Prepare to Catch Plate (mm)
17. Verify whether the plate is properly secured by all the XY bar suction cups when being lifted from the cassette. If one or more of the suction cups do not fully secure the plate, remove the XY bar cover and:
    1. Verify that the correct number of spacers are present for each suction cup. If the correct number of spacers is not present for each suction cup, install or remove spacers, as required. Then:
    2. Inspect the XY bar suction cup vacuum tubes for kinks or damage. If found, straighten kinked tubes, and/or replace damaged tubes as required, and repeat step 16. If the problem persists:

    3. Verify that the XY suction cup vacuum level is correct by using a vacuum gauge to check the vacuum level. If it is not correct, adjust the vacuum level, as required.

18. Verify that the paper/metal detector is functioning properly. If it is not:
    • Adjust the paper/metal detector, as required.
      Note: Use the new procedure only.
    If the problem persists:
19. Verify that the correct values have been entered for the following plate separation parameters in the registry:
    Note: It is recommended to use the default values for these parameters. If it is necessary to change them, do not change them by much.
    • Utilities>Hardware\Loading System\Loading System\Load Plate\From Cassette To Punch Entry Stage "Y Plate Rel Up In Cassette (mm)
    • Utilities>Hardware\Loading System\Loading System\Load Plate\From Cassette To Punch Entry Stage "X Rel Backward For 03 (mm)
20. Perform the steps described in, "Before You Finish".

Technical contact(s)

Itai Peperovich

Submitted by

Boris Gendlesman

Date submitted

24 Apr 2002