A technical bulletin that contains instructions for Loading Metal-Backed Plates on ThermoFlex Wide I Devices is posted on the Reference and Procedures pages.

The color of the optical glass in the TFX Head Front Window (30-1170A ASSY,OPT,FRONT WINDOW,TFX) has changed from blue to orange due to a change in vendor. The functionality has not changed. This information is posted on the TFX Parts/Tools page.

The inverter used in the drum vacuum drive has been replaced. See the FCOs page for kit number and procedure.

See ThermoFlex Wide I Operator Guide - German on the Reference page.

See ThermoFlex Wide I Operator Guide - French on the Reference page.

CTK Viewer and TIFF Assembler 2.1 have been replaced by TIFF Assembler Plus. See the TIFF Assembler Plus site for more information. ThermoFlex TIFF FE replaces TIFF Front End and TIFF Front End Lite.

The ablative media filters for the Debris Removal Cabinets (Morgan cabinets) are no longer available. A one-time upgrade kit is available to enable the Morgan cabinets to use UDRC filters. This kit can also be installed by customers. For details on the upgrade kits and procedure, see the FCOs page.

The manufacturer replaced the drum vacuum pump motor with a new one. For details on the upgrade kits, see the FCOs page. To download the drum vacuum drive programming instructions for the new motor, see the Procedures page.

The drum vacuum pump that was used previously is obsolete and has been replaced. The ECO has been delayed but some units have already been shipped to the field under a deviation permit. A label with the wording “New Vacuum Pump Inside - New DVD Programming Required” is located on the drum vacuum enclosure. The Programming the Drum Vacuum Drive procedure has been updated to include information for both types of pumps. Note that old programming for a new pump will result in OL2 errors on the DVD. This procedure is posted on the Procedures page.

CSC-PSS contact information for CAP has been added to the Escalation page.

The escalation process and contacts have been updated. See the Escalation page for details.

The specifications for the 5067,5280, and 3648 have been updated and consolidated into one specifications document. The new specifications are available on the overview page.

UDRC-BF and UDRC-LF are replaced on ThermoFlex Wide devices with the UDRC-BP with external venting as the default. See the UDRC parts page for details.

A new technical bulletin on replacing the UDRC filters on ThermoFlex devices has been posted. See the Reference page for details.

A procedure has been posted that describes how to adjust the device for use of 0.185 in. and 0.217 in. media. See the Procedures page for details.

Controlled release version 2.1 has been posted. See the Control/settings page for details.

A new Technical Bulletin has been posted on the media taping requirements for Flexo media. See the Reference page for details.

External venting will soon be possible for the UDRC cabinet. The firmware is under development and should be ready for release in a couple of months, along with an upgrade procedure. In the meantime, the site requirements have been revised to permit installation of external venting ducts. See the Installation page for the latest Site Preparation Guide (73-3186A-K).

On the recent version of the PolyScience chiller, which is a grey model rather than black, there is an error in the interface connector on the back. The interface has a cable detect that signals the device firmware to turn the coolant pump and the compressor on/off, but some chillers have the incorrect interface installed. See the Chiller Troubleshooting page for a workaround that will fix the cable detect and give some control over the chiller. A field change order (FCO) will be issued later to provide a permanent fix.

The new Flexo Media Imaging Performance Database provides imaging performance information (qualification status and imaging parameters) on the Flexo media that are either qualified or in beta for use on Creo Flexo systems. The database replaces both the Flexo Media Calculator and the Flexo Media Qualification spreadsheet.

Always Enable Macros when opening the file, and follow the instructions on the first page. For best results, download the spreadsheet to your local hard drive.

A new Debris Removal Nozzle has been released to reduce the noise level of the current nozzles. See FCO CA02695 for details.

During 2002-2003 a total of 16 TFX heads were returned. Five of these heads had failed laser diodes and were repaired. However, eight heads were determined to be working correctly and after extensive testing they were returned to stock. In most cases, no information was submitted with the returned head. To save time and money in the factory, we need to know what is wrong with a head. If you know that a head works and are returning it for re-sealing, simply include a note stating “Working head, returning for re-seal”. If a head doesn’t work, then our repair team needs a brief description of the problem. Also send any relevant log files (and the serial number of the head) to the TFXHeads@creo.com email account. The “No Fault Found” heads are costing Creo money. Shipping costs average US$950. Typical turn around time is about 2 months. During this time the head counts towards inventory and the calculated cost of this inventory is US$1300 per head. Therefore, every time the bag containing a head is opened unnecessaraly, it costs Creo more than US$2000. TFX heads are very reliable - please do all you can to ensure it really is a defective head before you replace it. The product specialists are available to offer a second opinion if you need one. (Contact info for the specialists is available on TechPlanet or from the Escalation link below).

Creo MPE devices are no longer being shipped with metal oxide varistors (MOVs) and spark gaps between line and ground. The MOV assembly (part number 10-3562B) should be removed from units in the field (serial numbers FX61 and earlier) at the next PM visit. See FCO CA01804 for details.

The installer file for Service Shell v2.4 SP1 is generating an error message when NVS parameters are backed up. The message will read:

• Timeout waiting for:
• OK
• From this command
• stg verify flash

To avoid this problem, download the updated Service Shell v2.4 SP1 Firmware Upgrade Script from the Service Shell Downloads page and install it on any machine where the Firmware installer file release date is prior to 15 Aug 2003.

A new Technical Bulletin has been posted that describes how to create curves in Harmony to prevent creation of scum dot in non-printing areas of flexographic plates. This workaround compensates for the inability of Harmony to change target tints of less than 1%. This document assumes the reader is familiar with using Harmony to derive Calibration curves, using Current and Target curves, and knows how to specify Harmony curves in Prinergy process plans. See the Reference page for details.

The Drum Speed Upgrade document has been updated. The old kit (02-4486A) has been replaced with a new kit (518-00071A). See the Upgrades page for details.

The following documents have been updated:

• TFX Head Window cleaning procedure (72-3458A-B).
  Window cleaning procedure added
  Photos updated
• DVD Programming procedure (77-0092A-B).
  Complete list of programming settings added

A Technical Bulletin on the orientation setup of TIFF Front End has been published:

• See the TFE Setup technical bulletin for details.

The following documents have been updated:

• ThermoFlex Installation Procedure - 73-0212A-B.
  DVD testing procedure added
  Chiller temperature setting updated
  
• ThermoFlex Site Preparation and Requirements - 73-3186A-J.
  LAN requirements updated
  Document template updated

The Installation document (73-0212A-A) currently specifies that the chiller temperature be set to 30º C. This is incorrect. The correct setting is 23º C. Use this setting for any new chiller installations and change any chillers that are currently set to 30º C to 23º C.

Focus learn errors can occur due to incorrect taping of media on the drum. See the Focus Learn Error technical bulletin for details.

Risk of defect identified with TFX Optical Window, P/N 30-1170A.
Some of the TFX head windows manufactured in the past year are defective. The nature of the defect means the window will not withstand repeated cleaning, possibly causing image artifacts. The root cause of the problem is a defective anti-reflective coating on the bare window (purchased). There is no way of knowing how many of these defective windows are at customer sites, and unfortunately there is no way to check in the field if a window is defective or not. To date, the problem has only surfaced at one site.

Corrective Plan
• All stock in Vancouver has been checked.
• All service stock worldwide will be pulled & checked for defective windows.
• TFX heads in service stock will be left as is.
• There is no need to take special action at customer sites, but please be on the lookout for any unexplained image artifacts. If you see this, order a new front window for the customer and ask them return the old window to Creo Vancouver, attention Lois Jacques (3225 Kincaid St Burnaby BC, V5G 4M1).

The manufacturer of the Drum Vacuum Drive Inverter, (15-1323, DRIVE,INVERTER, 460VAC,3-PH,21A,10HP), recommends that the unit be cleaned with compressed air every six months to avoid contamination building up on the unit's cooling fans. Contamination build-up on the fans can cause the unit to fail. See the 6 Month Preventative Maintenance Checklist.

When installing a Drum Vacuum Drive system, the wiring continuity to the overheat thermistor inside the drum vacuum pump must be checked prior to powering up. Using a multimeter, measure the resistance between the terminals "SC" (RED wire) and "S4" (BROWN wire) inside the inverter (15-1323), and ensure the resistance is around 200 ohms. If this reading is infinite (open circuit), then there is a break in the wiring somewhere, and must be checked. The DVD system will not operate correctly if there is an open circuit condition across these two terminals (the LCD will read "EF4", or External Fault 4). See the ThermoFlex Wide Installation procedure or contact Ian Skinner for more information.

Some media setup documents required the MIS value to be set to 9600. This value has been revised to 12000 for F-speed devices (drum speed of 320 rpm) and 15600 for V-speed devices (drum speed of 440 rpm). The documents affected are the ThermoFlex Media Setup Procedure, the Dupont Cyrel Setup procedure, and the Precision Coatings Film Setup procedure. These documents can be found on the TechPlanet Flexo Media page. See also the TFX Head firmware version 1.14 Release Notes (chapter 8).

A new document has been posted that describes how to load PCI film on a ThermoFlex device. The document can be found on the Procedures Page under the sub-heading of Media.

The acoustic foam installation kit must only be installed on customer request. See the FCOs Page for details.

ThermoFlex adopts a new naming convention:
Former convention:
ThermoFlex 2630
ThermoFlex 4048
ThermoFlex 3648, 5067, 5280

New convention:
ThermoFlex Narrow
ThermoFlex Mid
ThermoFlex Wide (note: within the "Wide" model, there are 3 different maximum plate size options, but these will remain unnamed and will only be defined in the specifications)

The version 2.0 Controlled Release CD is now available for the ThermoFlex device (FCO CA00224). This version improves support for V-speed imaging, and allows for mode media to be changed when using metric units in Print Console. As part of the controlled release, the TFX head firmware is upgraded to v1.14. For details, see Controlled Release v2.0.

A Controlled Release is a package of software/firmware components that have been tested for compatibility with each other and with ThermoFlex hardware. All machines should be upgraded to the latest controlled release version at the next visit.

In production, the Morgan Debris Removal Cabinet has been replaced with the Universal Debris Removal Cabinet (UDRC), starting with FX041. At existing installations, Morgan cabinets will be repaired if they fail, not replaced with the UDRC. The upgrade kit and procedures that were released under FCO E565 have been withdrawn, and its priority is changed from Next Failure to FYI.

Fretting on contacts between the cable and sensor causes a loss of connection. At next failure, a new cable and sensor should be installed to improve reliability. For details, see FCO E897.

If the firmware error message 19002 displays, and the ThermoFlex device has the latest debris nozzle (50-2130C) and a UDRC-BF, there are a few simple steps to follow. See the 19002 Troubleshooting Note for details.

A new procedure has been posted that explains how to upgrade a TFX head to V-Speed. Find it on the Procedures page of the TFX site, or download the TFX Head V-Speed Upgrade Procedure.

The Surface Depth Series in the ThermoFlex script bundle (see the Downloads page) does not work due to ThermoFlex firmware changes. To run a surface depth series, use PLOT <pattern> SD <start> <increment>.

If wavy artifacts appear during a plot and then abruptly stop, an air fitting on the carriage may have shifted. See the troubleshooting note for photos of the artifacts and details on how to correct the problem.

This news item is withdrawn, November 2002: At existing installations, Morgan cabinets will be repaired if they fail, not replaced with the UDRC. ECO E565 will apply to new shipments only.

Refer to the flexo plate specifications spreadsheet for drum speeds, imaging times and head power for qualified media (Thermoflex VLF devices only). The setup information includes drum speeds and exposure information for both V-speed and F-speed devices for a given media type. See the link under Drum Speeds, Head Power and Imaging Times on the Media page. Make sure that you enable macros when opening this spreadsheet.

The TFX Head ProComm scripts have been updated for use with MPE firmware 1.40. See Controlled Release v1.1 for instructions on upgrading to the new firmware. See the Downloads page for the new ProComm scripts.

The old debris removal nozzle upgrade kit 05-0245 is being replaced by nozzle upgrade kit 05-2046 (Morgan cabinets only). See FCO E845 for details.

Part numbers for belts, cylinders, fans, motors, power supplies, relays, sensors, switches, valves, and upgrade kits have been added to the site. See the Parts page under Parts by Type for all the links.

The version 1.1 Controlled Release CD is now available for the ThermoFlex (FCO E911). This version fixes known problems with MPE firmware 1.40 and Service Shell 2.30 installation. As part of the FCO, the TFX head diagnostic port must be connected to the TFE server, and the monitor screen requires additional setup in Service Shell.

A Controlled Release is a package of software/firmware components that have been tested for compatibility with each other and with ThermoFlex hardware. All machines should be upgraded to the latest controlled release version at the next visit. For details, see Controlled Release version 1.1 on the Control-Settings page.

To set the flow control needle valve on the DHU when used with the TFX head, simply open it all the way and leave it. The internal orifices in the DHU are adequate, so no flow adjustment is needed.

See the Connectivity page for a link to Accugraphics screen sets for ThermoFlex Wide Web with Dupont Cyrel media.

Creo has a contract with Rx Monitoring Services in Manchester, NH (603-666-6606 ext201) to provide Power & Environmental Site Surveys for the NAFTA region. The monitoring service includes voltage, current, temperature, humidity, dust and air pressure. Rx will provide the equipment to be installed at the customer site (for a maximum of 10 days), monitor it and send an e-mail report.

Air pressure monitoring is the latest addition to the Power & Environmental Site Survey. See Installing the Rx Air Pressure Sensor for details.

A Controlled Release is a package of software components that have been tested for a specific device configuration. Firmware Engineering has released v1.0 for ThermoFlex 5067F/5280F Base (MPE).
Note: ThermoFlex CR 1.0 has been withdrawn (April 24/02). Version 1.1 will be released to fix a bug with MPE firmware v1.40.

MPE Firmware v1.40 has been released. For details, see the firmware versions page. Troubleshooting notes are also available for two known problems with MPE firmware v1.40. See imaging status bar stalls and operator prompts stall.

Use the "drum tick" command to help troubleshoot encoder issues. For detailed instructions, see Firmware Engineering's drum tick page.

Test files are available online on the Downloads page. Due to the size of the files, they will not be included on the TechPlanet CD set.

A new debris nozzle has been designed which does not need adjustment or maintenance. This ECO covers implementation of the new debris removal nozzle with Morgan cabinets. For details, see FCO C967.

Machines that are having head focus problems, and are FX35 or earlier, may need to have the head diagnostic cable that is mounted inside the machine grounded. A bracket (57-9559A) is available to attach the diagnostic cable to the power box.

Refer to the Installing the Diagnostic Cable Bracket procedure for details.

The Dehumidifier Unit installation procedure has been updated to include flexo devices. See the Procedures page for details.

The media setup procedures have been updated and are available on the TFX Head Procedures page. If you are not familiar with TFX Head setup procedures, use the ThermoFlex Media Setup Procedure in conjunction with the Media specific Technical Notes. More experienced CSEs can use the Media specific Technical Notes only.

This zip file contains sd series, manual focus series, tint series, and head power series scripts. Download it here.

The purpose of this upgrade is to prevent ablative media from entering the optical cavity and to reduce maintenance costs. See ECO E346 for details.

See the TFX troubleshooting guides for details.

Static electricity can cause flexo media to stick to the table surface, making it difficult to move. To minimize the buildup of static electricity on the table surface, use an anti-static spray on the table as needed.  Please ensure that the customers in your area get a copy of the Technical Bulletin published on the Reference page.

Specifications have been updated or added for ThermoFlex 3648F (72-3520A-A), ThermoFlex 5067F (72-3326A-E), and ThermoFlex 5280F (72-3327A-E). See the Overview page.

The ThermoFlex 2630 beta specifications (72-3366A-B) have been published on the Overview page.