• Double picking of plates caused by humidity, static, and burrs
• Dropping of plates into a spinning drum
• During unload, plates with curl towards the emulsion side are striking the bottom of the plate ledge

• Install plate ledge teeth for plates to drag across during the pick
• Install unload air jets to the plate ledge to deflect the plate away from the table

1. Update the firmware to Version 1.20 .
2. Read the release notes first, not after you have problems.
3. Enable the double plate detect in the >>SET MEDIA "x" parameters.
4. To test the double plate detect, manually load 2 plates and try to plot.
5. After the test, in Procomm capture a >>LIST STATS and email it along with the machine serial number to smontague@creo.com

Installing the plate ledge teeth and unload air jets:
The present air knife (tube) is mounted to the plate ledge by a number of black plastic clips. This upgrade replaces two of these clips with deflector brackets under the ledge and teeth on top of the ledge.

1. Open the operator door. Turn the laser safety key in the power box to mechanical hazards.
2. Enter >> SET AL PCS 0 to disable the bay door sensor so that you can move the picker around.
3. Enter >>PICKER UP, then >>RAMP IN.
4. Cut the tie wraps holding the air knife to the ends of the plate ledge.
5. Unsnap the air knife out of the clips with a downward jerk.
6. From the right hand side of the table, count over 4 clips and unscrew that clip from the ledge.
7. From the left hand side of the table, count over 5 clips and remove that clip.
8. Lower the plate ledge by 2mm:
   Place a ruler on the plate ledge and mark a point 100mm up on the table with a pencil. Repeat for the other end. Now loosen the counter sunk screws that hold the ledge on and loosen the two bay door bumpers that also hold the ledge in place. Then move the ledge down until your ruler shows 102mm on both sides. Retighten. Do not use Loctite.
9. Fasten the air jet bracket up from the bottom of the ledge using a M3x8 screw and heavy washer (there are extra in the kit). Don't overtighten the screw as it will bend the ledge teeth. The jet should be angled down toward the load ramp.
   Helpful Photos:
   Fig 1: Plate ledge teeth
   Fig 2: Location of teeth on the plate ledge
   Fig 3: Photo of single air jet (N95) from under the ledge
   Fig 4: Location of air jet brackets
   Note: For TS3 machines the tubing coming from the unload air jet brackets should be heading toward the RIGHT of the machine (where the manifold is located).
   For TS3/8 and TS4 machines the tubing coming from the unload air jet brackets should be heading toward the LEFT of the machine (where the manifold is located).
10. The M3x8 ( see step 7) screws up into the plate ledge teeth (milled down M6 screw thread). Be sure to use Loctite 222 (10-3334) or you will be visiting this site again soon. In some cases you may have to file the hole in the ledge just slightly.
11. Zip tie the unload air jet tubing along the air knife and reinstall the air knife. Tie wrap the air knife to the ends of the plate ledge. Use  >>PICKER AJET ON to make sure that the center of the air jets are angled backward, hitting the load table 3 inches above the plate ledge.
12. Route the tubing through the hole in the bottom of the load table post by the separator arm on the right hand side for a TS3 (left hand side for TS3/8 or TS4). Continue to the engine manifold. Make sure that the tubing is clear from any moving parts.
13. Enter >>RAMP OUT.
14. The unload air jets connect to the upper ramp cylinder RED tubing with a "Y" fitting at the manifold. For machines with manifold on the right, see photo Fig 5 N95 connection at the engine manifold. For machines with manifold on the left, see photo Fig 6 N95 connection at the engine manifold.
    Disconnect the RED upper ramp cylinder tube from the manifold. Connect the short length of tube exiting the unload air jet tube "Y" quick connect into the manifold. Now insert the ramp cylinder tube into the "Y" quick connect. When the ramp is "in", some air is also diverted through the air jets. Various fittings are supplied since early machines used 1/4" tubing instead of 5/32". Use what you need.
15. Test that the connections are correct by entering >>RAMP IN, air should be blowing down the face of the load ramp. When the RAMP is OUT the jets should be off.