ColorQuick/Clarios

Service Manual
Customer Service

Toll-Free Hotline (USA, Canada): +1 866 GMI SERVice (+1 866 464-7378)
All Other Countries: +1 972 290-3121
Fax: +1 972 722-1132
E-mail:
Service and Tech Support: [email protected]
Parts Requests: [email protected]
Web site: www.avt-inc.com

USA Office European Office

AVT-Dallas AVT EMEA SCRL

10460 Miller Road Mechelsesteenweg 132
Dallas, TX 75238 B-2860 Sint-Katelijne-Waver
USA Belgium
Telephone: +1 972 290-3120 Telephone: +32 (0)15 56 03 80
Fax: +1 972 722-1128 Fax: +32 (0)15 55 39 97

AVT Office

AVT LTD
6 Hanagar St., P.O. B 7295
Hod-Hasharon 45241
Israel
Telephone: +972 9 761-4444
Fax: +972 9 761-4555

Unpublished copyright © 2010 Graphics Microsystems, Inc. All rights reserved. This document
is the property of and contains information proprietary to Graphics Microsystems, Inc. No part
of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or
translated into any language or computer language, in any form or by any means, electronic,
mechanical, magnetic, optical, chemical, manual or otherwise, without the written permission
of Graphics Microsystems, Inc.

Graphics Microsystems’ products are covered by one or more of the following United States
patents: 4864930, 5052298, 5543922. Microcolor is a trademark of Graphics Microsystems,
Inc. registered in the U.S. Patent and Trademark Office. Microsoft, Windows, Access and
Excel are trademarks of Microsoft Corporation. Other brands and their products are trade-
marks or registered trademarks of their respective holders and should be noted as such.

P/N 067S030130-EN Rev B (EO 16630)

 Contents
Warnings ............................................................................................................ vii
1 Introduction ....................................................................................................... 1
2 System Overview .............................................................................................. 3
2.1 Clarios System Description ..........................................................................3
2.2 Clarios System Components Overview........................................................5
Clarios Workstation Computer .....................................................................6
Clarios Server Computer..............................................................................7
On-Press Computer .....................................................................................8
Color Manager Computer.............................................................................8
Network Connections ...................................................................................8
2.3 Powering On the Clarios System .................................................................9
Reset Clarios Server Computer .................................................................11
2.4 Exiting Clarios and Turning Off Clarios Workstation Computer .................12
2.5 On-Press Power .........................................................................................13
3 Customizing the System ................................................................................. 15
3.1 Utilities View - Configuration ......................................................................15
3.2 Display Options ..........................................................................................16
3.3 User Selections ..........................................................................................17
3.4 Preferences................................................................................................19
3.5 Tolerance Groups ......................................................................................21
Create a New Tolerance Group .................................................................22
Duplicate a Tolerance Group .....................................................................23
Remove a Tolerance Group .......................................................................23
3.6 Passwords..................................................................................................24
Set Security Levels.....................................................................................25
Set User Policy Rights................................................................................25
3.7 Sampling Rules ..........................................................................................26
Create a New Sampling Rule .....................................................................27
Duplicate a Sampling Rule .........................................................................28
Remove a Sampling Rule...........................................................................28
3.8 Paper Classes ............................................................................................29
Name Paper Classes .................................................................................29
3.9 Ink Manufacturers ......................................................................................30
Name Ink Manufacturer..............................................................................30
3.10 Paper Types.............................................................................................31
Create a New Paper Type..........................................................................32
Duplicate a Paper Type..............................................................................34
Remove a Paper Type ...............................................................................34
3.11 Ink Types..................................................................................................35
Create a New Ink Type...............................................................................36
Duplicate an Ink Type.................................................................................41
Remove an Ink Type ..................................................................................41

Clarios Service Manual Contents iii

 3.12 Color Bar Configuration............................................................................42
Remove a Color Bar...................................................................................43
4 Color Bars ....................................................................................................... 45
4.1 Clarios Color Bars ......................................................................................45
FFMR Color Bar .........................................................................................45
4.2 Color Bar Types .........................................................................................46
Primary Types ............................................................................................46
Secondary Types .......................................................................................46
4.3 Installing Color Bar Files ............................................................................46
4.4 Before Making Changes.............................................................................46
4.5 Color Bar Menu ..........................................................................................47
4.6 Importing or Deleting Color Bars ................................................................48
5 Maintenance.................................................................................................... 49
5.1 Cleaning Clarios Probe Head & Calibration Plaque ...................................49
Step 1 - Remove the Probe Head ..............................................................51
Step 2 - Clean the Probe Head ..................................................................53
Step 3 - Clean the Spectrophotometer.......................................................54
Step 4 - Clean the Camera and Flash........................................................55
Step 5 - Clean the Calibration Plaque ........................................................56
Step 6 - Test the Probe Heads...................................................................56
5.2 Checking Overhead Brackets and Fasteners for On-Press Units ..............57
6 Replacement Parts.......................................................................................... 59
6.1 Clarios Workstation Computer ...................................................................59
Replace Clarios Workstation Computer .....................................................60
Restore Files to New Computer after Replacement...................................60
6.2 Clarios Server Computer............................................................................61
Replace Clarios Server Computer..............................................................61
Restore Files to New Computer after Replacement...................................61
6.3 On-Press Computer ...................................................................................62
6.4 Scan Head .................................................................................................64
6.5 Quadrature Encoder Assembly ..................................................................65
6.6 Press Signal Interface ................................................................................66
6.7 Calibration Cover .......................................................................................67
6.8 Roller Guards .............................................................................................68
6.9 Idler and Measure Rollers ..........................................................................69
6.10 Servo Drive Assembly ..............................................................................70
Servo Drive Assembly Removal.................................................................70
Servo Drive Assembly Replacement..........................................................71
Test Servo Drive Assembly ........................................................................71
6.11 Torque Specifications...............................................................................72
7 Diagnostics...................................................................................................... 73
7.1 Manual Color Bar Locate ...........................................................................75
Color Bar Setup Section.............................................................................77

iv Contents Clarios Service Manual

 Color Bar Images Section ..........................................................................78
Manual Color Search Section.....................................................................78
7.2 Locate Fixture Center.................................................................................81
Results Area...............................................................................................82
Controls ......................................................................................................83
Message Box..............................................................................................83
7.3 System Tests .............................................................................................83
Test Results ...............................................................................................85
Control Buttons...........................................................................................85
7.4 Head Target Alignment ..............................................................................86
Head Target Alignment Section .................................................................87
Controls ......................................................................................................88
Message Box..............................................................................................88
7.5 Web Watch.................................................................................................89
Web Watch Control ....................................................................................91
Web Watch Results....................................................................................95
Plot Displays...............................................................................................97
7.6 Color Compliance Check ...........................................................................98
Install the Color Standard...........................................................................98
Start Color Compliance Check Procedure .................................................99
Color Compliance Check Results.............................................................102
Revision History .............................................................................................. 103
Index ............................................................................................................... 105

Clarios Service Manual Contents v

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vi Contents Clarios Service Manual

 Warnings
WARNING: Warning labels as shown at left indicate the hazard
zones on the equipment. DO NOT place hands or
clothing near any moving machinery at any time.

WARNING: Each scan head travels on three V-rollers mounted to

the V-rail. Hands or fingers could be injured at these
points. DO NOT place hands or clothing where they can
become entangled with the V-rails or V-rollers.

Figure 1: V-Rail and V-Roller Hazard Areas (two on top, one on

bottom)
WARNING: While the On-Press has power, the scan heads may
move at any time.

WARNING: Opening the enclosure door turns off power to the

On-Press unit. The terminal block and 24V power
supply in On-Press enclosure have live AC power when
the enclosure door is open and the On-Press is
switched off.

CAUTION: Opening door turns power off

ATTENTION: L’ouverture des portes coupe l’alimentation
CUIDADO: Al abrir la puerta el sistema se apagará
ACHTUNG: Automatische Stromabschaltung bei geöffneter Tür

Clarios Service Manual Warnings vii

 WARNING: Installation by a Graphics Microsystems-trained
specialist only.

WARNING: The rollers on the Clarios On-Press move at high

speed. Hands or fingers could be injured by the force
of the rollers. DO NOT place hands or clothing where
they can become entangled with the rollers. DO NOT
place hands or clothing in the path of the moving scan
heads.

WARNING: Not to be put into service until equipment which

incorporates Clarios is safe for use.

ATTENTION: The attention of the specifier, purchaser, installer, or user is

drawn to special measures and limitations to use which must be observed
when the product is taken into service to maintain compliance with the
directives indicated in the EU Declaration of Conformity. Details of these
special methods and limitations are available on request, and are also
contained in the product manuals and installation procedures. Moreover,
this equipment must not be put into service until the machinery into which
it is incorporated has been declared in conformity with the provision of all
other relevant EU directives.

Servicing the Clarios System

Most GMI components contain no serviceable parts and may present an

electrical hazard, as indicated by this label.

Customer Service can assist you if system components need to be

exchanged or replaced.

viii Warnings Clarios Service Manual

 Isolation Transformer
(no user serviceable parts)
Clarios Computer
(no user serviceable parts)

Figure 2: Warning Labels on Clarios Workstation Console

Crush hazard areas

Warning label: Scan heads
between scan head
may move at any time
and frame
On/Off Lamp, On-Press
Scanner Power Switch,
and Warning label (power
switch will not stop press)

Warning label: Opening

door turns power off

UPS warning label

Interlocked door (opening

V-Rail pinch
door turns power off)
hazard areas
at rail top and
Isolation Transformer
bottom
On/Off Lamp (no user serviceable parts)

On-Press Scanner
Power Switch Clarios On-Press Computer
(will not press unless (no user serviceable parts)
specially wired) Warning label: Power
switch will not stop press

Figure 3: On-Press Warning Labels and Hazard Areas

Clarios Service Manual Warnings ix

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x Warnings Clarios Service Manual

 1 Introduction
This manual is for use with Graphics Microsystems’ Clarios system, an
on-web color measurement system.

Typographic Conventions

To make this manual easier to follow, bold letter are used to show touch-
control buttons, icons, or view names, such as OK, Apply, or Press
Status.
Note: Notes contain specific information. They may explain why a
certain step should be performed. Sometimes they contain tips
about a particular step in a process.

Helpful Hint

Helpful Hints appear at the end of sections. They contain tips on how to
use the Clarios system more effectively.
WARNING: Warnings appear when specific instructions must be
followed to avoid creating a problem.

Clarios Service Manual Introduction 1

 This page is intentionally blank.

2 Introduction Clarios Service Manual

 2 System Overview
This section describes the Clarios system components, how the system
operates, and how to power On/Off the Clarios server application and the
Clarios workstation and monitor.

2.1 Clarios System Description

The On-Press scanners measure the density of points in the color bar for
each form running on the press. The measurements are sent from the On-
Press computer to the Clarios server application.

The Clarios server application compares the density readings to the target
densities and sends density changes to bring color to the targets. The
results appear on the Clarios workstation monitor.

After the press has had a chance to settle with the new ink levels, the
On-Press scanners restart the process by scanning the color bar again.

Since each form can be different, the Clarios system needs information
about the form and its color bar. This information is received by the Clarios
workstation via the Clarios server application.

For more information on operating the Clarios system, see the Clarios
Training & User’s Guide and the Clarios Advanced User’s Manual.

Clarios Service Manual System Overview 3

 NetBEUI &
TCP/IP
Ethernet
`

Clarios Workstation Clarios Application Server Color Manager

Low-level
NetBEUI /
Hardware
Ethernet
Interfaces
Clarios Workstation
On-Press Module
TCP/IP/ Probe
Head
Ethernet Enclosure

Servo Servo
Transport
Amplifier Motor

On-Press
Servo Servo
Transport
Amplifier Motor
Press Event
Signals PLC
Probe
Press Speed Head
Optional Encoder
Signals

Figure 2.1: Clarios System

4 System Overview Clarios Service Manual

2.2 Clarios System Components Overview
The system components include:
• Clarios On-Press Scanner
One to two scanners move across one or more webs to measure
density and other elements in the color bar.
The On-Press scanner has two probe heads that give real-time
density, measurement, and other data. The scanner receives requests
from the Clarios server application, and in turn, sends the real-time
data back to the Clarios server application.
• Clarios Server Computer and Application
All job data is created by the operator with the aid of CIP3 presetting, if
enabled, and sent to the Clarios server application (running on the
Clarios server computer). The Clarios server application captures the
data and sends it to the Clarios workstation. The Clarios server
application also receives runtime data from scans.
• Clarios Workstation
The Clarios workstation consists of a computer inside a console and a
touchscreen monitor on top of the console.
The Clarios workstation receives system configuration, job, and
runtime scan data from the Clarios server application. The Clarios
workstation monitor displays scan results and job folders on a touch-
controlled screen. The operator touches buttons and menus on the
screen in the same way as they use a mouse or trackball.
• Press Speed and Position Encoders
The encoders mount on the press and provide the Clarios workstation
with press speed and position information via the Clarios server
application.
• Press Event Sensors
Sensors receive event signals from the press and transmit them to the
Clarios workstation via the Clarios server application. Events such as a
speed change, blanket wash, or web splice cause the On-Press
Scanner to pause scanning until the event is cleared.
• Color Manager
Color Manager generates charts and reports based on the Clarios
workstation’s scan data.

Clarios Service Manual System Overview 5

 Clarios Workstation Computer
The Clarios workstation computer is located inside the Clarios workstation
console.

Figure 2.2: Clarios Workstation Computer (front view)

Figure 2.3: Clarios Workstation Computer (rear view)

This computer connects to the touchscreen monitor and the Clarios

Ethernet network.
Note: All newer touchscreens are USB, not COM.

Connectors are available to attach to an external mouse or keyboard, or to

a VGA monitor.

6 System Overview Clarios Service Manual

 Clarios Server Computer
The Clarios Server computer is located in the server rack.

Figure 2.4: Clarios Server Computer (front view)

Figure 2.5: Clarios Server Computer (rear view)

This computer connects to the press, the on-press units, the internal data
network for processing, and to VPN for remote support.

Clarios Service Manual System Overview 7

 On-Press Computer
The On-Press computer is located in the On-Press unit. It is connected to
the Clarios NetBEUI / Ethernet network, the probe heads, the Press
Events Signals PLC board, and the servo amplifier board.
NetBEUI /
Probe Head 1 Ethernet
Probe Head 2 Connection

Press Event
Signals PLC

Servo
Ground Strap Amplifier

Figure 2.6: On-Press Computer (rear view)

Color Manager Computer

The Color Manager computer connects to a monitor, keyboard, mouse,
and printer. It is connected to the Clarios network and to your Ethernet
network.

Printer

Keyboard
Mouse
Customer Ethernet
Ethernet Network Connection

Monitor
Modem

Figure 2.7: Color Manager Computer (rear view)

Network Connections
For information about network connections, see the Ethernet Installation
Guide, P/N 090S900074.

8 System Overview Clarios Service Manual

2.3 Powering On the Clarios System
To turn on the Clarios system, follow these steps.
1. Power on the On-Press module. (See “On-Press Computer” on page 8
and “On-Press Power” on page 13 for information on the On-Press.)
2. Power on the press console. (See the OEM or GMI Operator Console
Unit (OCU3) User’s Manual for more information.
3. Turn on the Clarios workstation computer, by pressing the power
switch on the front of the Clarios workstation computer.
Note: You must first turn on the Clarios workstation monitor by
pressing the power button located on the side or front,
depending on the type of monitor.
On/Off Switch

disc

Figure 2.8: Clarios Workstation Computer (front)

The Clarios server and workstation applications will start automatically.

• If the server application is not running, double-touch the Clarios

AppServer icon to start the server. If you need to reset the Clarios
server computer, see the steps for “Reset Clarios Server
Computer” on page 11.

• If the workstation application is not running, double-touch the

Clarios Client icon to start the workstation.

4. While the program loads, the “Connecting to Server” and “Loading

System Configuration” messages display on the Clarios workstation
monitor, as shown in Figure 2.9 on page 10.

Clarios Service Manual System Overview 9

 Figure 2.9: Connecting to Server and Loading System Data Messages

These messages should clear in 30-60 seconds.

5. After the system and job data have been received, the Press Status
view should display with the press units and green camera icons on
the Clarios workstation computer.

Figure 2.10:Press Status View on Clarios Workstation

10 System Overview Clarios Service Manual

 Reset Clarios Server Computer
WARNING: The Clarios Server computer, running the Clarios server
application, should always remain on. Turning it off will
disable all OPs and Clarios workstation computers. If a
reset is required, follow steps 1-6 below.

1. End the Clarios server application.

2. Delete the activejob.xml or jobqueue.xml file in the C:\GMI\CQ
directory.
3. Shut down Windows.
4. Restart the Clarios server application by toggling the On/Off power
switch on the front of the Clarios server computer to the On position.

On/Off Switch

Figure 2.11: Clarios Server Computer (front)

5. Verify that the Clarios server application has started. If not, start it
using the Clarios Client desktop icon.
6. Wait for the system to reconnect to the OEM, Clarios workstation
computer(s), and OPs. This may take up to 10 minutes.

Clarios Service Manual System Overview 11

2.4 Exiting Clarios and Turning Off Clarios Workstation Computer
Before turning off the Clarios workstation computer, the Clarios
workstation application must be closed.

Exit the Clarios Workstation Application

To close the Clarios workstation application, touch the Exit button at the
top of all views.
Exit button

Figure 2.12: Main Toolbar - Exit button

WARNING: Before turning off the Clarios workstation computer,

the Clarios application must be closed.

WARNING: Turning off the computer while the application is still

running may damage the system or form data.

Shut down Clarios Workstation Computer Using Windows XP

Figure 2.13: Shut Down Sequence

1. Touch the Start button on the Quick Launch toolbar. An expanded
menu displays
2. Touch the Shut Down button on the drop-down menu and the Shut
Down Windows dialog displays.
3. Make sure the drop-down menu displays Shut down and then touch
the OK button.

12 System Overview Clarios Service Manual

2.5 On-Press Power
Power to the On-Press unit is controlled by a yellow mushroom switch on
the outside of the enclosure.

WARNING: Power must be turned off using the enclosure power

switch before opening the enclosure door. Failure to do
this may harm the On-Press computer. There may still
be power inside the OP enclosure, even after pushing
the mushroom switch.

The enclosure door must be securely fastened before turning on the power
again using the mushroom switch. The enclosure door also has a power
switch. But using the door to turn the power on and off can cause
problems for the On-Press computer. If it takes more than one attempt to
fasten the door, that causes the power to cycle on and off quickly, harming
the computer.

On/Off Lamp

On-Press
Scanner
Power Switch

On/Off Lamp

On-Press Scanner
Power Switch

Figure 2.14: On-Press Power

Clarios Service Manual System Overview 13

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14 System Overview Clarios Service Manual

 3 Customizing the System
During installation, the Clarios system is set up to work with the press it is
installed on. The Display Options and User Selections on the Utilities -
Configuration view contain the specifications that are used to customize
the system.

This section explains these selections and how to set up job preferences.
Note: Changes to shop procedures may require changes to the Clarios
site configuration.

3.1 Utilities View - Configuration

Touch the Utilities View Selector button on the main toolbar to display the
Utilities - Configuration view. This is the default Clarios Utilities view.

Located on this view are three Display Options and nine User
Selections.

Main Toolbar
Configuration Utilities button

Display
Options User Selections

Figure 3.1: Utilities View - Configuration

Clarios Service Manual Customizing the System 15

3.2 Display Options
The Display Options buttons control how the Web Data views - Delta
Density, Scan Data, and Tone Value - present data.

Display options are set for:

• units
• numerics
• tolerance limits

Units

Indicates the display unit is in English.

Numerics

Select to Show or Hide numerics. Actual and target values are shown
next to the individual ink keys. A green line shows the target value relative
to the actual value.

Actual value

Target value (green line)

Figure 3.2: Show Numerics Option

Tolerance Limits

Select to Show or Hide tolerance limits. Tolerance limits are shown as

dotted gray lines.

Tolerance limits
(dotted gray lines)

Figure 3.3: Show Tolerance Limits Option

16 Customizing the System Clarios Service Manual

3.3 User Selections
The User Selections icons allow the installer and/or user to set up all
Clarios libraries. The installer/user can customize the default settings for
new forms, so that the computer automatically fills in the most commonly
used settings.

The following list of user selections are described in detail in the following
sections of this chapter.

Installer
User Selections Description Configurable
Only (*)

Preferences Set preferences for defaults. *

Set up density control limits and
Tolerance Groups *
process limits.
Control who can use advanced
Password
Clarios options.
Set up number of samples for
Sampling Rules *
templates and scans.

Paper Classes Set up to five paper classes. *

Ink Manufacturers Identify ink manufacturers. *

Identify the available paper
Paper Types *
types used for printing.
Setup standard ink names for
Ink Types process colors, black, and spe- *
cial colors.

Color Bar Configure color bars.

Configuration
*

Note: User selections noted by (*) can only be configured by the installer.

Clarios Service Manual Customizing the System 17

 Password Protected

To access the User Selections described in this chapter, a password must

be entered. This password is set during system configuration.
1. To access the User Selections, double-touch an icon and the
Password dialog displays.

******** password entry field

OK

Figure 3.4: Password Dialog

2. To enter the password, touch anywhere in the password entry field.
The alphanumeric keypad displays.

text entry
display field

OK

Figure 3.5: Alphanumeric Keypad

3. Using the keypad, enter the password by touching the keys and the
password displays in the text entry display field.
4. Touch the OK button to close the keypad.
5. The password displays as asterisks in the password entry field.
6. Touch OK to enter the password and close the Password dialog.

Access is now allowed to the User Selections.

18 Customizing the System Clarios Service Manual

3.4 Preferences
Note: This is installer configurable only.

You can specify default setting preferences for various parameters.

Double-touch the Preferences icon to open the Preferences dialog.

OK

OK Numeric Keypad

Figure 3.6: Preferences Dialog

Press Speed Display - FPM, IPH, or MPM

Set the Press Speed Display by touching feet per minute (FPM),
impressions per hour (IPH) or meters per minute (MPM).

Subtract Paper From All Densities

Touch the Yes / No toggle button to subtract/not subtract paper density

from all densities calculated by Clarios.

Allow Automatic Form Numbers

Touch the Yes / No toggle button. Clarios can automatically assign a form
number if Yes is selected.

Allow Alpha/Numeric Form Numbers

Touch the Yes / No toggle button. Clarios can automatically assign an
alphanumeric form number if Yes is selected.

Allow Automatic Switch to Salable Scan

Touch the Yes / No toggle button. Clarios can switch automatically to
salable mode from makeready. This happens only when two consecutive
history scans are within tolerance.

Clarios Service Manual Customizing the System 19

 High and Low Value For % In Tolerance Display (Ink Keys)
• High
Specify the upper value for a quality range for percentage of ink keys
in tolerance. Percentages above this value cause the PIT button to
display as green, indicating high quality. Percentages below this value,
but above the Low Value cause the button to display as yellow,
indicating a quality warning.
• Low
Specify the lower value for a quality range for percentage of ink keys in
tolerance. Percentages below this value cause the PIT button to
display as red, indicating a quality warning. Percentages above this
value, but below the High Value cause the button to display as yellow.
If the low and high PIT values are both set to zero (0), this feature is
disabled.

Follow these steps to change the High or Low values:

1. Touch the High or Low Value field and the numeric keypad opens.
2. Enter the new high or low value by touching the number keys and then
touch .
3. The new High or Low Value displays in its respective field and the
keypad closes.
4. Touch OK to save the default setting preferences and close the
Preferences dialog.

Cancel
1. To cancel the changes, touch the Cancel button. A message box
displays asking “Do you want to save changes?”.

Figure 3.7: Preferences Message Dialog Box

2. Touch Yes button to save the changes and close both dialog boxes.
3. Touch No button to cancel the changes and close both dialog boxes.
4. Touch the Cancel button to close the Preferences message box and
return to the Preferences dialog.

Note: For all User Selections, follow steps 1 through 4 to cancel

changes.

20 Customizing the System Clarios Service Manual

3.5 Tolerance Groups
Note: This is installer configurable only.

The tolerance groups determine the density process and control limits for
all forms. A tolerance group is assigned to each press unit. Fifteen
tolerance groups may be added to the library.

Limits: Each group must specify a control limit and process limit
between 0.00 and 3.00 for target densities. The control and
process limits are symmetrical ranges (+ and -).

Note: The tolerance limits for Density Solid can have two meanings. If
less than 1.00, they represent absolute density points (abs) from
the target density. If greater or equal to 1.00, they represent a
percentage (%) of the target density.

Double-touch the Tolerance Groups icon to open the Tolerance Group

Setup dialog.

New Duplicate Tolerance Name field

Tolerance
Group
List

Select
Swatch
Type

Control
Limit &
Process
Limit
Densities

Total
Tolerance
Groups
field
Apply

OK

Figure 3.8: Tolerance Group Setup Dialog

Clarios Service Manual Customizing the System 21

 Create a New Tolerance Group
1. Touch the New button and TG1 displays in the Tolerance Group List
and the Tolerance Name field. The number in the Total Tolerance
Groups field is increased by one.
2. To name the new tolerance group, touch the Tolerance Name field
displaying TG1 and the alphanumeric keypad displays.
3. Enter the new tolerance group name by touching the keypad keys. The
new name displays in the text entry display field of the keypad.
Touch and the new name displays in the Tolerance Name field
and the keypad closes.
4. Select Swatch Type for the new tolerance group by touching any of
the swatch buttons. The selected button displays as depressed.
5. Select Control and Process Limits for the selected swatch by
touching each of the control or process limit fields in sequence:
> Density (abs)
> dL* (lightness difference between a sample and target)
> da* (red-green difference between a sample and target)
> db* (blue-yellow difference between a sample and target)
> dC* (Chroma difference between a sample and target)
> dh* (hue angle difference between a sample and target, relative to
0°)
> dH* (metric hue difference between a sample and target, relative to
the two hues)
As each control or process limit field is touched, the numeric keypad
displays. Enter the new value for the control or process limit by
touching the number keys. Touch to close the keypad.
The new process or control values display in their respective fields.
6. Touch the Apply button to apply all the attributes to the new tolerance
group. The new name now displays in the Tolerance Group List.
Note:If you select the OK button instead of the Apply button, the
Tolerance Groups Message box displays the message “Do
you want to save changes unapplied?”.
7. Touch OK to close the Tolerance Group Setup dialog.

22 Customizing the System Clarios Service Manual

 Duplicate a Tolerance Group
1. At the Tolerance Group List, touch and highlight the name of the
tolerance group to be copied.
2. Touch the Duplicate button and TG2 displays in the Tolerance Group
List and the Tolerance Name field.
3. Follow steps 2 through 7 in “Create a New Tolerance Group” on
page 22.

Remove a Tolerance Group

1. At the Tolerance Group List, touch and highlight the name of the
tolerance group to be removed.
2. Touch the Remove button and the tolerance group name is deleted
from the list and the number in the Total Tolerance Groups field is
decreased by one.
3. Touch OK to close the Tolerance Group Setup dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

Clarios Service Manual Customizing the System 23

3.6 Passwords
Up to three levels of passwords are allowed for active system options
indicated in the figure below. Each level may use a different password.

Double-touch the Password icon to open the Passwords Dialog.

Security
Levels

Active
User
Rights

OK

Figure 3.9: Passwords Dialog Box

24 Customizing the System Clarios Service Manual

 Set Security Levels
1. Touch Level 1 (High), Level 2 (Middle), or Level 3 (Low) fields and
the alphanumeric keypad displays.
2. Touch the keys to enter a password in the appropriate box (up to 8
characters).
3. The password displays in the text entry display field of the keypad.
Touch and the keypad closes.
4. The new password appears in the password entry field as a row of
asterisks.

Set User Policy Rights

1. Set the User Rights Policy for each of the three levels for each of the
active system options listed below.
> Change Configuration: Customize the Clarios system.
> Change Calibration: System component replacement
procedures.
> Access Diagnostics: Clarios maintenance and troubleshooting.
> Change Tolerance Rules: Specify the process and control limits
used in displaying scan results.
> Access Ink Library: Enter the ink names.
> Change Templates: Make a reusable template from a form.
> Access Note: Enter list of notes to be displayed when the Notes
icon is pushed. The notes selected for the scan appear in reports.
> Add Color Bar: For systems configured for the multiple color bar
option, you can password-protect adding additional color bars.
2. After entering the information, touch OK to save the changes and
close the Passwords dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

Clarios Service Manual Customizing the System 25

3.7 Sampling Rules
Note: This is installer configurable only.

Sampling Rules control how frequently the scan results are saved as
samples and how frequently the heads scan.

When Clarios is installed, the installer enters the press’s makeready and
running speeds. These speeds are labeled Sample Level 1 FPM and
Sample Level 2 FPM. These speed levels appear in the Sampling Rules
dialog automatically. The default values are 500 FPM and 1000 FPM.

Set the number of impressions between sample scans when the press is
running at makeready, and when in salable mode at slower than Sample
Level 1 FPM, between Sample Level 1 FPM and Sample Level 2 FPM,
and faster than Sample Level 2 FPM. Sample results are saved with the
form.
Note: The maximum number of impressions between sample scans is
30,000.

Double-touch the Sampling Rules icon to open the Sampling Rules

dialog.

New Duplicate Name

Edit
Speed
Levels
Sampling
Rules List
Sample
Level
fields

Impressions
Total Between
Rules Sample
field Scans

Apply

OK

Figure 3.10: Sampling Rules Dialog Box

26 Customizing the System Clarios Service Manual

 Create a New Sampling Rule
1. Touch the New button and SRule1 displays and is highlighted in the
Rules List and the Current Rule Name field. The number in the Total
Rules field is increased by one.
2. To name the new sampling rule, touch the Name field and the
alphanumeric keypad displays.
3. Enter the new sampling rule name by touching the keypad keys. The
new name displays in the text entry data field of the keypad. Touch
and the new name displays in the Current Rule Name field and
the keypad closes.
4. Select speed levels for the new sampling rule by touching the Edit
Speed Levels button. Since this button is password protected, the
Password dialog displays.
> Touch the password entry field and the alphanumeric keypad
displays. Enter the password by touching the keys. The new
password displays in the password field as a row of asterisks.
Touch OK to close the Password dialog.
5. The Impressions Between Report Sample Prompt fields are now
activated and Sample Level 1, Sample Level 2, and Sample Prompt
may be set for the new sampling rule.
6. Touch each field in turn and the numeric keypad appears. Enter the
new sample level and touch . The new sample level displays in its
respective field and the keypad closes.
7. Select the number of impressions between sample scans for the new
sampling rule by touching each of the following fields in turn:
> Make Ready (any speed)
> Salable (< 500 FPM)
> Salable (500 to 1000 FPM)
> Salable (>1000 FPM)
8. When the numeric keypad displays, enter the new value by touching
the number keys and then touch to close the keypad. The new
value displays in its respective field.
9. Touch the Apply button to apply all changes to the new sampling rule.

Note: If you select the OK button instead of the Apply button, the
Sampling Rules message box appears displaying the message
“Do you want to save changes?” .

10. Touch OK to save the change and close the Sampling Rules dialog.

Clarios Service Manual Customizing the System 27

 Duplicate a Sampling Rule
1. At the Rules List, touch and highlight the name of the sampling rule to
be copied.
2. Touch the Duplicate button and SRule2 displays and is highlighted in
the Rules List.
3. Follow steps 2 through 10 in “Create a New Sampling Rule” on
page 27.

Remove a Sampling Rule

1. At the Rules List, touch and highlight the name of the sampling rule to
be removed.
2. Touch the Remove button and the sampling rule name is deleted from
the list and the number in the Total Tolerance Groups field is
decreased by one.
3. Touch OK to close the Sampling Rules dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

28 Customizing the System Clarios Service Manual

3.8 Paper Classes
Note: This is installer configurable only.

Double-touch the Paper Classes icon to open the Paper Classes dialog.

Five paper class names may be added to the library.

OK

Figure 3.11: Paper Classes Dialog Box

Name Paper Classes

1. Touch any of the Class 1 through Class 5 fields and the alphanumeric
keypad displays.
2. Enter the new name, touch to close the keypad, and the new paper
class name displays in its respective field.
3. Touch OK to save and close the Paper Classes dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

Clarios Service Manual Customizing the System 29

3.9 Ink Manufacturers
Note: This is installer configurable only.

Double-touch the Ink Manufacturers icon to open the Ink Manufacturer

dialog.

Five ink manufacturer names may be added to the library.

Apply
Current Ink
Supplier

Total OK
Suppliers
field

Figure 3.12: Ink Manufacturers Dialog

Name Ink Manufacturer

1. Touch MFG1 - MFG5 in the Ink Suppliers list. The selected name
displays in the Current Ink Supplier field.
2. Touch the field and the alphanumeric keypad displays. Enter the name
for the manufacturer by touching the keys and touch to close the
keypad.
3. The name displays in the Current Ink Supplier field and the Apply
button is enabled.
4. Touch Apply to apply the changes and then OK to close the Ink
Manufacturer dialog.
Note: If you select the OK button instead of the Apply button, the Ink
Manufacturers Message dialog appears displaying the message
“Do you want to save changes?”.
5. Touch Apply and then OK to save the change, and close the Ink
Manufacturer dialog.

Cancel Changes
To cancel changes, follow steps 1 through 4 in the Cancel section on page
page 20.

30 Customizing the System Clarios Service Manual

3.10 Paper Types
Note: This is installer configurable only.

Up to 20 paper types can be entered into the paper types library with
information on classification, manufacturer, grade, and weight.

The first paper type in the list is used by the system as the default for all
forms. When a new paper type becomes the default, all form templates are
updated automatically. A different paper type can be selected for a form in
Job Management view if necessary.

See the Clarios User’s Manual for more information.

Double-touch the Paper Types icon to open the Paper Types dialog.

Name

New

Target

Paper
Type
Name Class
List

Grade

Weight
Total
Paper Apply
Types
field OK

Figure 3.13: Paper Types Dialog

Clarios Service Manual Customizing the System 31

 Create a New Paper Type
1. Touch the New button and PaperType1 displays in the Paper Type
Name List and Name windows. The number in the Total Paper Types
window is increased by one.
2. To name the new paper type, touch the Current Paper Type Name
field and the alphanumeric keypad displays.
3. Enter the new paper type name by touching the keypad keys. The new
paper type name displays in the text entry data field of the keypad.
Touch and the new paper type name displays in the Paper Type
Name List field and the keypad closes.
4. Select a manufacturer for the new paper type by touching the name in
the Manufacturer list. The new manufacturer displays in the
Manufacturer field.
5. Select a weight for the new paper type by touching one of the five
paper weight buttons, 20#, 40#, 60#, 80#, or 120#. The selected
button displays as depressed and the weight displays in the Weight
field.
6. If the correct weight is not shown on the buttons, touch the Weight
field and the alphanumeric keypad displays.
7. Enter the new paper weight by touching the keypad keys and then
touch to close the keypad. The new paper weight displays in the
Weight field.
8. Select a grade for the new paper type by touching one of the five grade
buttons, 1-5. The selected button displays as depressed and the grade
displays in the Grade field.
9. If the correct grade is not shown on the buttons, touch the Grade field
and the alphanumeric keypad displays.
10. Enter the new paper grade by touching the keypad keys and then
touch to close the keyboard. The new paper grade displays in the
Grade field.
11. Select a class name for the new paper type by touching one of the five
Class buttons. The selected button displays as depressed and the
class name displays in the Class Name field.

32 Customizing the System Clarios Service Manual

 12. Select target values for the new paper type by touching the Targets
button to display the Target Setup dialog.

Target
Density
field

Figure 3.14: Target Setup Dialog

13. Touch the Target Density field and the CQClient Message box
displays.

Figure 3.15: CQClient Message Box

14. Touch the OK button and the numeric keypad appears. Enter a target
density value for the paper by touching the keypad keys.
15. Touch to close the keypad and the new target density value
displays in the Target Density field.
16. Touch OK to save the new target density value and close the Target
Setup dialog.
17. Touch the Apply button on the Paper Types dialog to save the
changes to the new paper type.
Note: If you select the OK button instead of the Apply button, the
Paper Types Message dialog appears displaying the message
“Do you want to save changes?”.
18. Touch OK to save the change and close the Paper Types dialog.

Clarios Service Manual Customizing the System 33

 Duplicate a Paper Type
1. At the Paper Type Name List, touch the name of the paper type to be
copied and it becomes highlighted.
2. Touch the Duplicate button and PaperType 2 displays in the Paper
Type Name List and is highlighted.
3. Follow steps 2 through 18 in “Create a New Paper Type” on page 32.

Remove a Paper Type

1. At the Paper Type Name List, touch the name of the paper type to be
removed and it becomes highlighted.
2. Touch the Remove button and the paper type name is deleted from the
list.
3. The number in the Total Paper Types window is decreased by one.
4. Touch OK to close the Paper Types dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

34 Customizing the System Clarios Service Manual

3.11 Ink Types
Note: This is installer configurable only.

The ink library contains standard ink names for process and special inks.
Up to 100 ink names may be entered.

An ink library entry has these values: Ink Name, Filter, Display Color, and
Tolerance Rule. These four values are replaced in the inker if a new ink
library entry is selected from the list.

Double-touch the Ink Types icon to open the Ink Setup dialog.

New Ink Name

Ink Ink
Type Manufacturer
List
Display
Color
Filter

Ellipsis
Default
Total Tolerance
Ink
Types Default Color
field Symbol

Targets

Apply
OK

Figure 3.16: Ink Setup Dialog

Clarios Service Manual Customizing the System 35

 Create a New Ink Type
Note: If the operator is adding an ink type that will be run the same as
an existing ink, use the duplicate process instead of creating a
new ink.
1. Touch the New button and N1 displays in the Ink Type List and Ink
Name fields and is highlighted. The number in the Total Ink Types
field is increased by one.
2. Touch the Ink Name field and the alphanumeric keypad displays.
3. Enter the new ink name (up to four characters) by touching the keypad
keys. The new ink type name displays in the text entry data field of
the keypad. Touch and the new ink type name displays in the Ink
Name field and the keypad closes.
4. To add a description of the new ink type, touch the Description field
and the alphanumeric keypad displays.
5. Enter the description by touching the keypad keys. The new ink type
name displays in the text entry data field of the keypad. Touch
and the new ink type description displays in the Description field and
the keypad closes.
6. Select a Default Ink Manufacturer for the new ink type by touching
one of five buttons, Manufacturer1, Manufacturer2, Manufacturer3,
Manufacturer4, or Manufacturer5. The selected button displays as
depressed.
7. Select a Display Color by touching one of the four color buttons, K, C,
M, or Y. The selected button displays as depressed and the selected
color displays in the Display Color field.
Display Color field

Display Color
Ellipsis button

Figure 3.17: Display Color buttons

The display color is the color used on the Results views when Clarios
displays scan results for the inker.

36 Customizing the System Clarios Service Manual

 8. If the desired color is not shown on the four buttons, touch the Display
Color Ellipsis button. The Color dialog displays.

Basic Colors palette

Color
Display
field

OK

Figure 3.18: Color Dialog

9. Select the new color changes by touching the desired color from the
Basic Colors palette. It displays in the Color Display field.
10. Touch OK to save the color and close the Color dialog. The new color
displays in the Display Color field.
11. Select a Filter for the new ink type by touching one of the four buttons,
K, C, M, or Y. The selected button displays as depressed.

Figure 3.19: Ink Filter Buttons

The filter is used to measure the ink density for each inker and is the
measured color with the darkest density.
To select a filter, you must first measure a sample of the color with a
handheld. The readings on the handheld densitometer show the
densities for all four colors. Select the highest reading for the best filter.

Clarios Service Manual Customizing the System 37

 12. Select a Default Tolerance for the new ink type by touching the
Default Tolerance Ellipsis button.

Default Tolerance
Ellipsis button

13. The Tolerance Groups search dialog opens.

Go
Search field

Tolerance
Group
List

OK

Figure 3.20: Tolerance Groups Search Dialog

14. Select the desired Tolerance Group for the new ink type by touching
the name in the list, or perform a search for it.
The Tolerance Group specifies the process and control limits used in
the Results views.
> Limits - Each Tolerance Group must specify a control limit and
process limit between 0.00 and 3.00 for target densities. The
control and process limits are symmetrical ranges (+ and -).
> Control limit - displays as a dashed line in the Key Position view.
Values are acceptable if they fall inside the control limits.
> Process limits - outer limits mark the maximum variation.
> Tolerance rule values - are +/- the targets. The tolerance rule is
used when displaying scan results for the inker, as shown in the
Results views, and in making ink key move recommendations in
closed loop.

38 Customizing the System Clarios Service Manual

 15. To perform a search, touch the Search field.
> When the alphanumeric keypad displays, enter the name by
touching the keypad keys. The name displays in the text entry
data field of the keypad.
> Touch the button and the name displays in the Search field
and the keypad closes.
> Touch the Go button to start the search.
16. When the desired name displays in the field, touch OK to select it and
close the Tolerance Groups dialog.
17. Select the Default Color Symbol for the new ink type by touching one
of twelve buttons, K, C, M, Y, or S1 - S8. The selected button displays
as depressed.

Figure 3.21: Default Color Symbols

18. Selecting the Targets Manufacturer1-5 list Default button causes the
button to display as depressed and adds the default target values to
the new ink type.

Figure 3.22: Targets Manufacturer and Default Buttons

Target values are the values at which the inkers are preset. The
default value is set at 0.01.
Note: Entering a new target density value will set all targets for the
new ink type to the value entered into the Target field of the
Target Setup dialog.

Clarios Service Manual Customizing the System 39

 19. Selecting any of the Targets MFG1 - MFG5 buttons causes the Target
Setup dialog to display.

Paper
Type
buttons

Target
Values for
Swatches

OK

Figure 3.23: Expanded Target Setup Dialog

20. Select a class name by touching one of the five Class buttons. The
selected button displays as depressed and the CQClient message box
displays.

Figure 3.24:CQClient Message Box

21. Touch the OK button to close the CQClient message box. The cursor
starts to blink in the Target Density window.
22. Touch the Target Density window and the CQClient message box
displays again.
23. Touch the OK button to close the message box and the numeric
keypad opens.

40 Customizing the System Clarios Service Manual

 24. Enter a target value for the selected class by touching the keypad
keys, and then touch to close the keypad.
25. Touch the Apply button to save the changes.
Note: The new value displays in the Target Density field when the
class button is touched.
26. Touch OK to save the changes and close the Target Setup dialog.
27. Touch the Apply button and then OK to save the changes and close
the Ink Setup dialog.
Note: If you select the OK button instead of the Apply button, the
Ink Types message box appears displaying the message “Do
you want to save changes?”.

Duplicate an Ink Type

1. At the Ink Type List, touch and highlight the name of the ink type to be
copied.
2. Touch the Duplicate button and the selected ink type displays in the
Ink Type Name List and is highlighted.
3. Follow steps 1- 27 in “Create a New Ink Type” on page 36.

Remove an Ink Type

1. At the Ink Type List, touch and highlight the name of the ink type to be
removed.
2. Touch the Remove button and the ink type name is deleted from the
list and the number in the Total Ink Types field is decreased by one.
3. Touch the Apply button and then OK to save changes and close the
Ink Setup dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

Clarios Service Manual Customizing the System 41

3.12 Color Bar Configuration
Note: This is installer configurable only.

Systems using a single color bar use types Primary or Classic. Systems
configured for multiple color bars may use types Primary, Classic,
Secondary, and No Feature.

Double-touch the Color Bar Configuration icon to open the Color Bar
Configuration dialog.

Available
Color Bars
list
Delete

Import

OK

Figure 3.25: Color Bar Configuration Dialog

42 Customizing the System Clarios Service Manual

 Importing a Color Bar
1. Touch the Import button on the Color Bar Configuration dialog (as
shown in Fig. 3.25) to open the Open dialog.

folders drop-down menu

and files

File name

Open

Figure 3.26: Open Dialog

2. Use the drop-down menu at Look in to locate the file of the desired
color bar.
3. When the file name of the color bar to be imported is displayed in the
File name field, touch the Open button to download the new color bar
file and close the Open dialog.
4. The new color bar name displays in the Available Color Bars list and
the number in the Total Color Bars field is increased by one.
5. Touch OK to save the change and close the Color Bar Configuration
dialog.

Remove a Color Bar

1. At the Available Color Bars list, touch and highlight the name of the
color bar to be removed.
2. Touch the Delete button and the name is deleted from the Available
Color Bars list and the number in the Total Color Bars field is
decreased by one.
3. Touch OK to save the change and close the Color Bar Configuration
dialog.

Cancel Changes

To cancel changes, follow steps 1 through 4 in the Cancel section on page

page 20.

Clarios Service Manual Customizing the System 43

 This page is intentionally blank.

44 Customizing the System Clarios Service Manual

 4 Color Bars
WARNING: Changing the color bar installed by GMI Customer
Service may adversely affect the performance of the
Clarios system. Changes to the color bars should only
be made by trained personnel.

4.1 Clarios Color Bars

The color bar shown on the Clarios workstation monitor must precisely
match the color bar printing on the form.

GMI Customer Service provides custom color bars. To add a color bar
provided by GMI, see Section 4.3 Installing Color Bar Files. It is strongly
recommended that you do not change the setups for the color bars
provided by GMI Customer Service. If the color bar requires adjustment,
contact Customer Service.

FFMR Color Bar

The Following Form MakeReady (FFMR) color bar has small, specially-
shaped swatches to evaluate density. A GBT swatch is in every key of a
FFMR color bar.
The following figure shows a sample FFMR color bar.

3-Feature Locator Mark

GBT Swatch (3-FLM)
Feature

Clarios uses a spectrophotometer to measure and control color.

Spectrophotometer: An instrument for measuring and comparing the

intensities of the colors of the spectrum.

A densitometer measures how much light is absorbed by the ink and

substrate combination. Density is relative to the thickness of the ink film.
Clarios compares the measurement to a standard value (the target
density).
• Shop standard target densities are:

K: _____ C: _____ M: _____ Y: _____

• SWOP (Specifications for Web Offset Printing) standards are:

K: 1.60 C: 1.30 M: 1.40 Y: 1.00

Clarios Service Manual Color Bars 45

4.2 Color Bar Types
Clarios uses four types of color bars. If your system uses only one color
bar to a form, then your color bar is either a Primary or Classic color bar. If
your system is configured for multiple color bars, then it is possible you
may have any of the four types.

Primary Types
• Primary: The standard color bar with locator marks and non-solid
swatches that have a solid area around the swatch feature.
• Classic: A color bar with locator marks and non-solid swatches that
are completely non-solid (there are no solid areas within the swatch). A
non-solid swatch must be placed next to its corresponding solid swatch
(e.g., a cyan tint swatch must be placed next to a cyan solid swatch).

Secondary Types
• Secondary: Similar to the Primary color bar, but has no locator marks.
The non-solid swatches have solid area around the swatch feature.
• No Feature: There are no locator marks in the color bar and there are
no features in the swatches.

You must add a primary color bar before adding secondary color bars. You
can only delete a primary color bar after deleting secondary color bars.

4.3 Installing Color Bar Files

Clarios only supports importing color bars in the .csv format. These color
bars are imported using the Clarios workstation computer. See “Color Bar
Configuration” on page 42 for step-by-step instructions.

4.4 Before Making Changes

WARNING: Changing the color bar installed by GMI Customer
Service may adversely affect the performance of the
Clarios system. Changes to the color bars should be
made only by trained personnel.

If you must make or edit a color bar, it is extremely important that you first
take some time to analyze the color bar.
1. Study the color bar spreadsheet provided as an electronic file with the
color bar. The spreadsheet contains critical information such as
location, size, position, and color for each color bar element.
2. Most color bars have a pattern of elements (and sometimes gaps) that
repeat within the color bar. Examine the color bar sample to identify the
repeat, including any gaps.

46 Color Bars Clarios Service Manual

 3. Identify the beginning (first element on the left edge) and the end (last
element on the right edge) of the color bar. The beginning and end are
locked together, and are usually in the same position as the repeat.
Note: Each color bar has an index, indicating the center of the color bar.

4.5 Color Bar Menu

From any view, touch the Utilities View Selector button. At the
Configuration tab, double-touch the Color Bar Configuration icon to
open the Color Bar Configuration dialog.

Available
Color Bars
List
Delete

Import

OK

Figure 4.1: Color Bar Configuration Dialog

• Available Color Bars List

Displays a list of available color bars included in the library.
• Total Color Bars
Displays the total number of color bars available.
• Delete
Erase a color bar from the Clarios system’s active memory.
• Import
Import a .CSV file for use as a color bar.

Clarios Service Manual Color Bars 47

4.6 Importing or Deleting Color Bars
You can create a customized color bar using a spreadsheet program such
as Microsoft Excel, and import it into Clarios. The spreadsheet file must be
saved as a .CSV (comma-separated values) file, and its fields must
contain certain data.
WARNING: Changing the color bar installed by GMI Customer
Service may adversely affect the performance of the
Clarios system. Changes to the color bars should be
made only by trained personnel.

To import a .CSV file for use as a color bar, or to delete a color bar, see
“Color Bar Configuration” on page 42 for step by step instructions.

48 Color Bars Clarios Service Manual

 5 Maintenance
There are several Clarios parts that require regular maintenance by the
customer to ensure continued precise and safe operation of the system.
WARNING: Only trained personnel should service any On-Press
unit parts.

WARNING: Turn OFF all power to the On-Press unit before

servicing.
WARNING: On-Press unit maintenance should be performed when
the press is not running.

5.1 Cleaning Clarios Probe Head & Calibration Plaque

Perform the following steps as needed to maintain proper probe head
performance.

The frequency of this procedure will vary greatly depending on the

environmental conditions. Generally, factors that will increase the need for
this cleaning procedure include the following:
• Ink misting from unit nearest the probe head.
• Air supply turned off or house air is not clean and dry. Verify all air
hoses are connected and not clogged. Note that air supply should be
set just enough to detect the movement of air. A positive pressure is all
that is needed to keep the openings clean. High air volume is not only
wasteful, but can create a condition that causes dirt to be attracted to
parts critical to probe head functionality.
• Web breaks causing paper scraps to get lodged in probe head
openings.

For newspaper usage, it is recommended that the heads be cleaned every

two weeks. However, the cleaning interval depends on the usage of the
equipment, local environment, and the quality of the inks and papers used.

Clarios Probe Head Overview

This procedure is designed for use with Clarios probe heads, PN

055G400747-04 and 055G400747-08.

The probe head has a built-in camera for locating the color bar, a
spectrophotometer for measuring color, and a calibration plate inside the
On-Press cabinet to calibrate both the camera and spectrophotometer
during normal operation. To measure the color bar accurately and reliably,
all components must be dirt free.

Clarios Service Manual Maintenance 49

 The process to clean a single head takes about 30 minutes, and includes
removing, cleaning, and reassembling the head. Each GMI On-Press has
two heads, one for upper and one for lower surfaces. You should allow 60
minutes per GMI On-Press unit.

It is important to replace the same head on the same mounting plate after
cleaning. If the probe head is replaced or probe heads are swapped, the
probe head will need to be re-aligned using the realigning procedure for
probe head replacement.

Customer Supplied Supplies

1. Compressed air

Note: Canned compressed air is available from computer and office

supply stores. (Clean and dry internal compressed air may be
used as an alternate).
2. Press wash / ink cleaning solvent

Note: Available from screening and printing supply stores. (Product must
be clean and not recirculated.)
3. Flashlight
4. Scissors

Probe Head and Calibration Plaque Cleaning Kit Supplies

(PN 090G900730)
1. Cleaning solution, LCD
monitor (PN 037G600004)
2. Cloth, Microfiber
(PN 037G600003)
3. Applicator, cotton tipped
(PN Q54600005)
4. Cloth, Rags
(PN 037G600005)
Probe Head and Calibration Plaque
5. 9/64” Allen head tool Cleaning Kit (PN 090G900730)
(PN 039G200116)
6. .050” Allen head tool
(PN 039G200622)
7. Screw, #2 (2 provided)
(PN 031G101151-04)

Applicator (PN Q54600005)

50 Maintenance Clarios Service Manual

 Step 1 - Remove the Probe Head
Important: Turn power off to the
On-Press unit. A yellow button and
indicator light are provided on each
side of the cabinet that will de-ener-
gize the probe head motors if either
one is depressed. The indicator light
will go out.
Do Not Proceed any further until the
indicator light is off and power is
verified to be off.

If applicable, pull out on the guard locking screw and slide the guard
toward the gear side of the press. This will expose the probe head and
drive belt. Move the probe head out as shown in the following figure.
This will allow easy access to the mounting screw.

Disconnect the air supply hose on the back of the probe head. This is a
quick disconnect coupling. Remove the Allen Head 9/64-inch screw
using the tool provided.

Clarios Service Manual Maintenance 51

 Remove the second 9/64-inch Allen screw with the tool provided. The
probe head will remain on the mounting plate on two alignment pins.
Caution: With both screws removed, the probe head can fall off.
Gently pull it out, being certain you have a good grasp on the
probe head so it is not dropped. The probe head may require
gently rocking left to right, since the electrical plug and align-
ment pins are a tight fit.

52 Maintenance Clarios Service Manual

 Step 2 - Clean the Probe Head
Place the probe head on a solid surface, and plug the flash hole, cam-
era hole, and spectral hole with pieces cut to size from kit supplied
microfiber cloth (PN 037G600003). The cloth prevents cleaning solvents
from destroying the delicate optics.

Flash and Camera hole

Spectral hole

With the openings protected, clean the ink off the probe head housing
with customer supplied press wash / ink cleaning solvent and kit sup-
plied cloth rags (PN 037G600005). After the outside is clean, remove
the soiled microfiber cloths. The interior areas can now be cleaned.

Clarios Service Manual Maintenance 53

 Step 3 - Clean the Spectrophotometer
Using the Allen head wrench provided, remove the two small screws
holding the spectral cone to the probe head body. Clean inside of cone
using a clean piece of microfiber cloth dampened with kit supplied LCD
Screen Cleaning solution (PN 037G600004).

Spectral cone Spectral flash

With the cone removed, the spectral flash is exposed. This is a very del-
icate part. The first cleaning step calls for any loose debris to be blown
free using canned or dry compressed air. Be careful not to blow loose
debris down the spectral opening. The second cleaning step calls for a
clean piece of microfiber cloth to be dampened with LCD Screen Clean-
ing solution. Using the wood end of the kit supplied cotton tipped appli-
cator (PN Q546000005) and the cloth, gently wipe the area to remove
any remaining debris. Reinstall the Spectral Cone using new hardware
provided.

Note: The spectral optics should only have air blown inside to
clean them. If the spectral optics are contaminated, more
damage will be done attempting to clean them than by leav-
ing them alone. If the spectral optics are contaminated,
send the probe head back to GMI to be cleaned and rebuilt.
Replace with a spare probe head and follow the realigning
procedure for probe head replacement.

54 Maintenance Clarios Service Manual

 Step 4 - Clean the Camera and Flash
The camera and flash area may require cleaning several times to
ensure all ink and debris is removed. The first cleaning step calls for a
clean piece of microfiber cloth to be dampened with LCD Screen
Cleaning solution. Using the wood end of a cotton tipped applicator and
the cloth, gently wipe debris from the flash and camera area. Use
canned or dry compressed air to blow the flash area dry. Inspect with a
flashlight to confirm that the surface is clean.

Clean the camera opening. Inspect the camera opening for excess
debris. As a general rule it is not necessary to clean the camera surface
since the actual lens is far inside and typically remains clean. The risk of
damaging the camera by cleaning is high and should be avoided if pos-
sible. If debris is observed, blowing it out with canned or dry
compressed air is recommended. Remove the remaining debris if
necessary, using a clean microfiber cloth dampened with LCD Screen
Cleaning solution. Be extremely gentle when cleaning.

Re-mount the probe head on the

same rail where the probe head was
removed. It is important that the
probe head be replaced in the
position where it was removed or a
realignment procedure will need to
be done for the probe head to
function properly.

Note: Confirm that the probe head is flush with the mounting plate
prior to tightening the mounting screws.

Clarios Service Manual Maintenance 55

 Step 5 - Clean the Calibration Plaque
Inside the cabinet of each probe
head has an assembly with white
tiles and a black hole, that are used
to keep the camera and spectropho-
tometer in calibration throughout the
day. To access this area, remove the
spring-loaded cover. Wipe off exces-
sive ink using a clean microfiber
cloth dampened with LCD Screen
Cleaning solution.

Caution: Do not wipe tiles with

kit supplied rags. The
tiles can become
scratched and should
only be cleaned with a
clean piece of microfi-
ber cloth dampened
with LCD Screen
Cleaning solution.

The cup on the bottom can accumulate paper dust and should be
removed from the bottom of the assembly and blown out with canned or
dry compressed air. The black hole cup can be removed by twisting and
pulling down. Do not wipe the interior of the cup.
Gather all soiled cotton tipped applicators, rags, and cloths used in the
cleaning procedure and dispose of them properly.

Re-assemble the calibration plaque, close all covers, and then power-
on the On-Press unit.

Step 6 - Test the Probe Heads

See “System Tests” on page 83 for details on how to run a system test.

56 Maintenance Clarios Service Manual

5.2 Checking Overhead Brackets and Fasteners for On-Press Units
If your Clarios On-Press unit(s) are suspended from an overhead frame,
mounting brackets and fasteners must be checked for soundness and
tightness as part of your periodic plant maintenance program.
Note: Consult with GMI Customer Service if you have any questions
about adjusting the brackets or fasteners. See the inside front cover
of this manual for contact information.
• There are two sets of brackets and fasteners: a primary set and a
secondary set. Each set has sufficient strength to support one or two
On-Press units. The secondary fasteners carry the gravity load if the
primary fasteners fail. The vertical mounting bolts are intended to be
the primary fasteners.
• If there is a loss of web tram, the primary fasteners should be
examined. Do not use the fasteners as jacking screws to tram the On-
Press units. Use steel shims for tramming.
• No gaps should exist between closely fit surfaces of the On-Press unit
and the mounting brackets. If there are two units, there should be no
gaps between closely fit surfaces of the upper and lower On-Press
units.

overhead frame mounting brackets

primary fasteners upper On-Press unit secondary fasteners

secondary fasteners

lower On-Press unit

lateral stabilizing bar

Figure 5.1: Example Installation of Suspended On-Press Units (side view)

Clarios Service Manual Maintenance 57

 WARNING: The lateral stabilizing bars are not intended to provide
support for any additional gravity loads from people or
machinery placed upon them. If the lateral stabilizing
bars are to be used as a platform for operators or
machinery, additional structural members must be
added and configured so no additional gravity or
lateral loads are passed to the On-Press units.

58 Maintenance Clarios Service Manual

 6 Replacement Parts
When GMI Customer Service sends replacement parts, trained personnel
can install them according to the instructions in this chapter.

The following parts are user-replaceable:

• Clarios Workstation Computer • Press Signal Interface

• Clarios Server Computer • Calibration Cover
• On-Press Computer • Roller Guards
• Scan Head • Idler and Measure Rollers
• Quadrature Encoder Assembly • Servo Drive Assembly
• RIO PLC Speed Switch Devices (MUX)

Note: The Quadrature Encoder Assembly is not typical in Clarios installs.

Clarios typically uses an OEM supplied encoder.

6.1 Clarios Workstation Computer

Clarios Workstation
Computer (cables
attached in rear)

Figure 6.1: Clarios Workstation Console with Computer

WARNING: Exit the Clarios workstation application and shut down

the Clarios workstation computer using Windows
procedures, to avoid corrupting the Windows
operating system. Turn OFF power to the Clarios
workstation console before servicing.

NOTE: Computer models and enclosures may vary.

Clarios Service Manual Replacement Parts 59

 Replace Clarios Workstation Computer
1. After turning off power, open the front panel of the console.
2. Gently pull the computer part way out of the console, careful of the
cables still attached to the computer rear. Disconnect the cables from
the back. Place computer aside.
3. Connect the cables to the new computer, and secure them with the
screws. Place in console.
4. Turn computer power on.
Note: Before turning on the Clarios workstation computer, be sure
Color Manager and Clarios server computers/applications are
turned on and connected to the Clarios network.

Restore Files to New Computer after Replacement

1. After the old computer is replaced with a new computer, the power is
on, and the computer has fully booted, insert the GMI-supplied
removable media (thumb drive) into one of the computer’s USB slots.
2. Double-click the “My Computer” icon on the desktop.
3. Note the drive letter of the removable media.
4. Close the “My Computer” window.
5. Start the program by double-touching the “Clarios Client” icon on the
desktop.
6. At the prompt, enter the drive letter from step 3 (no colon (:) is
necessary). Then follow the on-screen instructions.
7. After the program completes and before removing the media from the
computer, look on the screen by the clock at the active icons. Find the
icon for “Safely Remove Hardware”, click on it, and select the
removable media device to be removed.
8. Remove the thumb drive from the computer and make sure that it is
still attached to the inside of the cabinet near the computer.
9. Power off the computer, using Shut Down, not Restart.
10. Close the door panel. Turn on power to the console and the computer.

Issues When Replacing Clarios Workstation Computer

• Make sure the time is correct. Windows sometimes changes the time
because the time zone was set.
• The Customer Net and GMI_NET interfaces may be reversed, and the
Clarios workstation computers may not communicate with the servers
as observed on the server program displays. This may occur because
Windows sometimes changes the order that the Ethernet interfaces
appear in the registry. This can be resolved by swapping the Ethernet
cables in the back of the computer. Contact Customer Service if
swapping the cables does not solve the problem.

60 Replacement Parts Clarios Service Manual

6.2 Clarios Server Computer

Replace Clarios Server Computer

WARNING: Exit the Clarios server application and shut down the
computer using Windows procedures to avoid
corrupting the Windows operating system. Turn off the
Clarios workstation console before servicing.

NOTE: Computer models and enclosures may vary.

1. After turning off the power, open the front panel of the console.
2. Gently pull the computer part way out of the console, careful of the
cables still attached to the computer rear. Disconnect the cables from
the back. Place the computer aside.
3. Connect the cables to the new computer and secure them with the
screws. Place the computer in the console.
4. Turn the computer power on.

Restore Files to New Computer after Replacement

1. After the old computer is replaced with a new computer, the power is
on, and the computer has fully booted, insert the GMI-supplied
removable media (thumb drive attached to inside the cabinet near the
computer) that contains the back up into one of the computer’s USB
slots.
2. Double-click the “My Computer” icon on the desktop.
3. Note the drive letter of the removable media.
4. Close the “My Computer” window.
5. Double-touch the “Clarios AppServer” icon on the desktop to start the
program.
6. At the prompt, enter the drive letter from step 3 (no colon [:] is
necessary). Then follow the on-screen instructions.
7. After the program completes and before removing the media from the
computer, look on the screen by the clock at the active icons. Locate
and click on the Safely Remove Hardware icon near the clock in the
task bar, and select the removable media device to be removed.
8. Remove the thumb drive from the computer and make sure that it is
still attached to the inside of the cabinet near the computer.
9. Power off the computer, using Shut Down not Restart.
10. Close the door panel and turn on the power to the console and to the
computer.

Clarios Service Manual Replacement Parts 61

 Issues When Replacing Clarios Server Computer
• Make sure the time is correct. Windows sometimes changes the time
because the time zone was set.
• The Customer Net and GMI_NET Ethernet interfaces may be
reversed, and the Clarios workstations and OP’s will not connect as
observed on the Print Quality Manager program display. This may
occur because Windows sometimes changes the order that the
Ethernet interfaces appear in the registry. This can be resolved by
swapping the Ethernet cables in the back of the computer. Contact
Customer Service if swapping the cables does not solve the problem.

6.3 On-Press Computer

WARNING: Only trained personnel should service any of the
On-Press unit parts.

WARNING: Turn OFF all power to the On-Press unit before

servicing.

1. Turn power OFF by tripping the dedicated breaker for the On-Press
unit.
2. Open the On-Press enclosure door and turn the computer’s power
switch to OFF.
3. Lift the computer gently out of the enclosure so that the nearest legs of
the chassis are outside the enclosure. Disconnect all cables. Remove
computer completely from the enclosure and place it aside.
4. Lift the replacement computer into the On-Press enclosure so that the
nearest legs of the chassis are outside the enclosure.
5. Connect the cables to the new computer and secure with the attached
screws.
6. Lift the computer and gently set it completely within the enclosure.
Make sure all cables are clear of any On-Press moving parts.

62 Replacement Parts Clarios Service Manual

 7. Plug in the power cord that runs between the isolation transformer and
the computer.

On-Press Computer
(cables attached this side)

Figure 6.2: On-Press Unit and Computer

8. Remove the compact flash from the old unit (as shown in the figure
below) and install it into the new unit.

Compact
Flash

Figure 6.3: On-Press Computer with Compact Flash

9. Turn on the computer power switch and close the enclosure door.

Issues When Replacing On-Press Computer

The compact flash could be defective. However, this is very unlikely

because GMI provides a special type of compact flash that is extremely
reliable. If the new unit doesn’t behave correctly, contact GMI Customer
Service.

Note: Service Note 398 provides steps for rescuing a compact flash card.

Clarios Service Manual Replacement Parts 63

6.4 Scan Head
WARNING: Only trained personnel should service any of the
On-Press unit parts, including the scan head.

WARNING: Before servicing, turn OFF all power to the On-Press

unit.

WARNING: Do not service the scan head while the press is

running.

1. Turn the power to the On-Press unit OFF using the power safety
switch. Be sure the press is not running.
2. Open the enclosure door and gently push the scan head to the middle
of the rail.
3. Remove the bolts, one on each side of the scan head, using a 9/64”
Allen wrench.

bolt
bolts

bolts
bolt

Figure 6.4: Scan Head

4. Attach the new scan head to the mount. Be sure to line up the posts
with the holes in the mount and seat the pins in the communication
port without bending them.
5. Use Loctite 222 or 242 on the bolts, and tighten to 25 in-lb of torque.
Be sure the head is flush to the mounting bracket, not angled up or
down.

64 Replacement Parts Clarios Service Manual

 Communication
Port

align posts

Figure 6.5: Scan Head and Scan Head Mount

6. Gently move the scan head back to the home position in the enclosure
and then back out again along the rail, to be sure it has unobstructed
movement.
7. Close the enclosure door and restore power to the On-Press unit.
8. Perform the Head Alignment Test. See Service Note 208 for the
complete head replacement procedure.

6.5 Quadrature Encoder Assembly

WARNING: Only trained personnel should service any of the
On-Press unit parts.

WARNING: Before servicing, turn OFF all power to the On-Press

unit.

WARNING: Do not service the encoder when the press is running.

The encoder is mounted on the press and returns information on press

speed and direction of paper travel. Each encoder assembly is mounted
depending on the unique press configuration, but the replacement
procedure is common to all presses.
1. Be sure the press is not running and power to the On-Press unit is off.
2. Loosen the screws on the encoder bracket, then remove the sensors
from the bracket.
3. Detach the cables from the sensors and set the sensors aside.
Note: Before detaching, mark the cables if they are not identified.
4. Attach the replacement sensors to the cables.
5. Insert the replacement sensors into the encoder bracket. Use an
oscilloscope to phase the encoders 90° apart.

Clarios Service Manual Replacement Parts 65

 If there is a bolt in the gear, offset the sensors so that they read only
the teeth of the gear all the way around and not the gap made by the
bolt.
gear

gear
bolt

bracket screws

Set gap at closest point encoder bracket

to 0.015”, +/-0.00.5)
sensor

Figure 6.6: Quadrature Encoder Assembly

6. The gap between the sensors and the gear must be set at the closest
point to 0.015”, +/-0.005”. Use a feeler gauge to set and check the gap.
Check the entire gear while jogging the press.
7. Tighten the screws on the encoder bracket. Use Loctite 222 or 242 on
the screws.

6.6 Press Signal Interface

WARNING: Only trained personnel should service any of the
On-Press unit parts.

WARNING: Before servicing, turn OFF all power to the On-Press

unit.

The Press Signal Interface (PSI) connects to the encoders, the press
event sensors, and the On-Press computer.
1. Be sure all power to the On-Press unit is off.
2. Open the door to the On-Press unit. The PSI is bolted to the right side
of the enclosure.
3. Note the location of all cables connected to the PSI, then detach.
4. Remove the PSI by removing the nuts with a 7/16” wrench. Set the PSI
aside.
5. Connect all cables (two encoders, the TCM cable to the On-Press
computer, and the press event sensors) to the replacement PSI.
6. Attach the PSI to the enclosure wall. Use Loctite 222 or 242 and
tighten the nuts to 100 in-lbs.

66 Replacement Parts Clarios Service Manual

 7. Close the On-Press unit door and power up the system.

Press Event Sensors

PSI
attachment

Encoder Encoder Sensor B

Sensor
X Encoder Sensor A

DB15 Connector to TCM Board

(to On-Press computer)

Figure 6.7: Press Signal Interface

6.7 Calibration Cover

WARNING: Only trained personnel should service any of the
On-Press unit parts, including the scan head.

WARNING: Before servicing, turn OFF all power to the On-Press

unit.

1. Turn off the power to the On-Press module.

2. Move the scan head out of the way by gently pushing it along the rail.
3. Detach the spring from the posts beneath the calibration holder. Slide
the cover off the end of the two shafts.
4. Slide the new cover along the shafts and attach the spring to the posts
beneath the calibration holder. Be sure the calibration cover slides
easily along the shafts and that it covers the calibration plaques and
black hole.

Figure 6.8: Calibration Cover

Clarios Service Manual Replacement Parts 67

6.8 Roller Guards
WARNING: Only trained personnel should service any of the
On-Press unit parts.

WARNING: Before servicing, turn OFF all power to the On-Press

unit.

WARNING: Do not service the roller guards while the press is

running.

Some models of the Clarios On-Press module may have roller guards.
There are a safety feature, designed to protect the hands from being
crushed between the scan head and the measure roller as the scan head
moves out of the enclosure.

There are roller guards for the 4-inch rollers (P/N 040G101932) and 8-inch
rollers (P/N 040G101933).
1. Be sure all power to the On-Press unit is off.
2. Loosen the four roller guard clamp screws using a 9/64” Allen wrench,
and remove the clamps.
3. Remove the roller guard and set it aside.
4. Put the replacement roller guard in place, making sure it is seated
properly against the roller bracket and the end frame. It should be clear
of the roller.
5. Replace the clamp screws. Use Loctite 222 or 242 on the screws and
torque them to 25 in-lb.

measure roller roller guard

roller guard clamp and screws

Figure 6.9: Roller Guard

68 Replacement Parts Clarios Service Manual

6.9 Idler and Measure Rollers
WARNING: Only trained personnel should service any of the
On-Press unit parts.

WARNING: Before servicing, turn OFF all power to On-Press unit.

WARNING: Do not service the rollers while the press is running.

Idler and measure rollers are the free-turning rollers that guide the web as
it passes through the On-Press unit.
Note: Rollers are trammed from the factory and should not need adjusting
when servicing idler roller bearings.

The scan head moves across the paper as the paper passes over the
measure rollers. Idler rollers help route the web to other press
components.
bolts

idler roller

measure roller

removable bracket top roller

Figure 6.10: Idler Rollers

1. Remove roller guard.
2. Remove the mounting bolts from the roller bracket at each end of the
roller. Use a 3/8” Allen wrench. Remove the top of the brackets.
3. Lift out the roller and set it aside. Insert the replacement roller, being
careful not to scratch it.
4. Replace the tops of the brackets. Insert the bolts. Use Loctite 242 on
the bolts and torque them to 106 ft-lbs.
5. Replace the roller guard, using Loctite 222 or 242 on the screws and
tightening the screws to 25 in-lbs.
6. When replacing a measure roller, GMI-trained personnel should align
the beams using the Clarios Beam Alignment Kit, GMI P/N
090G900107.

Clarios Service Manual Replacement Parts 69

6.10 Servo Drive Assembly
WARNING: Only trained personnel should service any of the
On-Press unit parts.

WARNING: Before servicing, turn OFF all power to the On-Press

unit.

What You’ll Need

Loctite 222 or 242 GMI P/N 037G200034

Torque wrench 30-250 in-lb. GMI P/N 039G200101
Wrench 3/16 long Allen 3/8 socket drive GMI P/N 039G200037

Servo Drive Assembly Removal

1. Turn off power to the On-Press unit by tripping the dedicated breaker
switch and turning off the power switch on the On-Press unit. Open the
cabinet door.
2. Disconnect the servo assembly cable from the servo interconnect
board on the end frame.
3. Loosen the two servo assembly mounting bolts. They are located on
the drive housing between the servo motor and the servo amp card.
4. Pull back on the servo drive assembly to compress the tensioning
springs. Slide the drive belt off the sprocket.
WARNING: Do not pull on the servo motor or servo amp card.
Grip the assembly from the bottom.
5. After the belt is removed, remove the mounting bolts and remove the
assembly from the On-Press unit.

mounting
bolts

pins

servo
motor servo
cable

Figure 6.11: Servo Drive Assembly

70 Replacement Parts Clarios Service Manual

 Servo Drive Assembly Replacement
1. Locate the two 1/8” pins on the back of the servo assembly bracket.
These pins line up with two slots on the drive housing.
2. Line up the two 1/8” pins with the breakout at the end of the slots on
the drive housing. Pull back on the servo drive assembly to compress
the tensioning springs in the slots.
WARNING: Do not pull on the motor or servo amp card.
Grip the assembly from the bottom.
3. Put Loctite on the two mounting bolts (1/4-20 x 1-1/2 SKTH). Install the
bolts with a washer and a split washer, but do not tighten. You have 10
minutes before the Loctite sets.
4. Again pull back on the servo assembly. Slide the drive belt onto the
sprocket. Be sure the belt and the sprocket grooves line up.
WARNING: Do not roll the belt onto the sprocket. This tears the
belt cords and causes belt failure.
5. Be sure the servo drive assembly fits flush to the drive housing, not
angled up or down.
6. Let the springs tension the belt. A slight jiggle of the assembly will help
seat the assembly.
7. Torque the two mounting bolts, installed in Step 3, to 101 in-lbs.
8. Connect the servo cable into the servo interconnect board on the end
frame. Be sure to secure with screws.

Test Servo Drive Assembly

1. Slowly slide the scan head out of its home position and check that all
belts ride smoothly in their sprockets.
2. Return the scan head to its home position again, while watching the
belts.
3. Close the enclosure door and power up the system.

Clarios Service Manual Replacement Parts 71

6.11 Torque Specifications
There are a number of screws and bolts used with the user-replaceable
parts. Refer to this chart for the correct torque.
Socket Head Alloy Steel
Hex Head Steel
Grade 8 (Black Color)
Grade 5
In Steel
Torque Torque Torque Torque
Size
ft-lb in-lb ft-lb in-lb
#2 0.5 6
#4 0.8 10
#6 1.6 19
#8 3.2 38
#10 4.8 58
1/4 12 144 6 72
5/16 24 288 14 168
3/8 43 516 24 288
7/16 68 816 39 468
1/2 106 1272 60 720
5/8 212 2544 120 1440
3/4 417 5004 212 2544
7/8 590 7080 315 3780
1" 901 10812 472 5664

Small Screws In Aluminum *

Torque Torque
Size
ft-lb n-lb
#2 0.3 4
#4 0.48 6
#6 1.04 12
#8 2.08 25
#10 3.36 40
1/4 8.4 101

Grade 8 alloy steel tensile strength is 150,000 psi. Grade 5 tensile strength
is 120,000 psi.

Note: Torques are with dry threads to 70% yield.

T = 0.2 x D x (yield strength x 0.7 x screw root area)

* Aluminum screw values are approximately 65% of steel.

72 Replacement Parts Clarios Service Manual

 7 Diagnostics
If the Clarios system is not operating properly, diagnostics can help you
determine what is wrong and how to fix it.

Touch the Utilities button on the main toolbar. On the Utilities view, touch
the Diagnostics tab to display the Diagnostics Selection List.

Utilities button

Diagnostics tab

Figure 7.1: Utilities View - Diagnostics Tab

Diagnostics Selection List
• Manual Color Bar Locate
Manually locate specific swatches on the color bar when the On-Press
is unable to do so automatically. This will adjust the LA (color bar)
position during an active form and does not make permanent changes.
• Locate Fixture Center
Manually locate specific swatches on the color bar and perform tests
on the selected swatch to determine color bar location. (This is done
by a GMI service technician.)
• System Tests
Perform tests of the servo, camera, and measurement systems of the
On-Press scanner to determine errors.
• Head Target Alignment
Manually locate specific swatches and perform tests on the selected
swatch to determine LC alignment difference.
• Web Watch
Allows installer to watch, collect, and analyze the printing of the press
and measurement characteristics of the Clarios system.
• Color Compliance Check
Allows installer to perform automated procedure that is used to verify
that the scanner conforms to color standards Status T or Status E.

Clarios Service Manual Diagnostics 73

 Password Protected

To access the Diagnostics Selections List described in this chapter, a

password must be entered. This password is set during system
configuration.
1. To access the Diagnostics Selections List, double-touch an icon and
the Password dialog displays.

******** password entry field

OK

Figure 7.2: Password Dialog

2. To enter the password, touch anywhere in the password entry field.
The alphanumeric keypad displays.

text entry
display field
OK

Figure 7.3: Alphanumeric Keypad

3. Using the keypad, enter the password by touching the keys and the
password displays in the text entry display field.
4. Touch the button to close the keypad.
5. The password displays as asterisks in the password entry field.
6. Touch OK to enter the password and close the Password dialog.

Access is now allowed to the Diagnostics Selection List.

74 Diagnostics Clarios Service Manual

7.1 Manual Color Bar Locate
When the On-Press is having difficulty locating specific swatches on the
color bar, the operator can find the swatches manually from the Manual
Color Bar view.
1. Touch the Manual Color Bar Locate icon to display the Diagnostics
view.

Camera
icons

Figure 7.4: Diagnostics View

2. At the Diagnostics View, touch a camera icon and the Diagnostics

message displays. The message asks: “Scanning must be stopped to
continue with this operation. Do you want to continue?”.
WARNING: Undertaking this diagnostic will stop Clarios from
controlling color on the press.

3. Touch the Yes button to continue and the Manual Color Bar Locate
dialog displays.

Clarios Service Manual Diagnostics 75

 Black
Color Bar bracket
Setup Section
large swatch

Color Bar Operator Gear Side

Setup Side
window Green bracket

Color Bar small swatch

Images Section

Camera image
displays here

Manual Color
Search Section Cancel

Arrows Done

message
box

Figure 7.5: Manual Color Bar Locate Dialog

76 Diagnostics Clarios Service Manual

 Color Bar Setup Section
This section of the dialog contains the Color Bar Setup window, with the
following subsections:
1. Operator Side, Gear Side – Operator and gear sides of the press are
shown graphically.

Operator side Gear side

Figure 7.6: Operator and Gear Sides of Press

2. Small Swatch – Small graphical swatch elements represent the
complete primary color bar.
black bracket

large
swatch

green
swatch

small
swatch
scroll

Figure 7.7: Small and Large Swatches

> The green bracket indicates a zoomed area of the color bar
image.
> The yellow vertical line indicates the center (not shown in the
figure).
> Red vertical line(s) (not shown in the figure) indicate the page
boundaries.
Touch a swatch in the Color Bar Setup window and the scanner goes
to that point on the web and scans. The images for that range of
swatches are displayed.
3. Large Swatch – displays a large graphical swatch of the primary color
bar showing:
> LA location scale
> image group area identification (green group line)
> center image identification (yellow group line)
> page boundary identification (red line and number)
Touch the swatch to select the center image and move the image
group area.
Touch the left and right scroll buttons to view other parts of the color
bar.

Clarios Service Manual Diagnostics 77

 Color Bar Images Section
A gray scale camera image of the color bar displays here. The image
rotation is determined by the system configuration.

Figure 7.8: Gray Scale Camera Image of Color Bar

Manual Color Search Section

Arrows

Use the arrow buttons in the Manual Color Search section to continuously
scan left, right, up, or down to locate the Locator Mark (LM).

Figure 7.9: Four Direction Arrow buttons

1. Up and Down arrows - Use to search up and down.
The up and down arrow buttons search the running direction of the
web. Touch the Cancel button and then the down arrow to begin
searching down. While searching up or down, push the left or right
arrow buttons to adjust the lateral search position by ±0.40cm (±0.16
in), and then continue searching up or down.
2. Left and Right arrows - Use to search left and right.
The left and right arrow buttons search across the web. If a possible
LM or swatch target is found, push the left or right arrow button to
search horizontally rather than vertically. The horizontal search
continues until another possible target is found. Touch the Cancel
button and then the up or down arrow buttons to stop the horizontal
search and begin the vertical search.
The default search direction is up.

78 Diagnostics Clarios Service Manual

 Cancel/Jump/Done Buttons
1. Cancel - Use this button to cancel actions.
> If pressed while searching, the search is canceled.
> If pressed while idle, the diagnostic operation is canceled with a
prompt to the operator to exit.

Figure 7.10: Cancel/Jump/Done Buttons

2. Jump - Use this button to adjust the search location.
The Jump button, if pressed while searching, adjusts the
circumferential search location by 1/2 (one half) of the cutoff length. If
the Jump button is pressed while searching left or right, the lateral
search location is adjusted by ±5.00cm (±2.00 inches).
3. Done
When the Done button is touched, a yellow box displays in the center
of the Color Bar Images Section of the dialog box.

yellow box selected

green box color
swatch

Touch the matching LM in the Color Bar Setup display. A green box
appears around the swatch. The program calculates the left-right
movement of the color bar. A message displays in the Manual Color
Bar Locate dialog.

The message asks: “Color Bar should be moved 2.00 cm (or 0.80 in) to
the RIGHT. Move the color bar and exit?”.

Clarios Service Manual Diagnostics 79

 Touch the Yes button to move the color bar and exit the Manual Color
Bar Locate dialog.
Note: White space around an LM helps Clarios find and identify the
LM. If you are using a LM rather than a 3-FLM (3-feature
locator mark), be sure that it is surrounded with the most
white space.
Note: 3-FLM locator marks do not require white space around
them.

Message Box

The Message box contains messages that describe actions taken at this
screen.

FOUND POSSIBLE SWATCH

Messages include:
• Initial search
• Searching up or down
• Searching left or right
• Cancel search
• Search aborted
• Found possible swatch
• Found possible LM

When a possible LM is located, verify its approximate position by checking

a printed sheet against the Color Bar Setup display. If this is the correct
LM, touch the Done button.

80 Diagnostics Clarios Service Manual

7.2 Locate Fixture Center
This option allows the GMI service technician to locate specific swatches
of the color bar and to perform tests on the selected swatch to determine
its LA position difference and suggest a new value.
1. Touch the Locate Fixture Center icon to display the Diagnostics
view.
2. At the Diagnostics view, touch the camera icon and the Locate
Fixture Center dialog displays.

Results
Area

Controls

Figure 7.11: Locate Fixture Center Dialog Box - in Process

3. Use the arrow buttons in the Controls section to search for the fixture
center.
4. When the Done button is touched, a Diagnostics dialog appears
asking: “Execute Test Procedure On Target In Image #1?”.

5. Touch the Yes button to execute the test procedure on the target.
When results are complete, the Auto Update dialog displays.

Clarios Service Manual Diagnostics 81

 6. Touch the Yes button to replace the Current value with the Suggested
value. These values are displayed in the Home-To-Center windows,
described in “Results Area” below.
7. Touch the Yes button to be able to type in a new value in the
Suggested value field described in “Results Area” below.

Results Area
This section of the dialog box contains the following subsections:
• Home-To-Center – Contains two fields:
> Current: Displays the current configuration value.
> Suggested: Displays the suggested configuration value when test
completes

• Impression – Displays the real-time test impression count.

• Of – Displays the expected test impression count.
• Difference – Displays the teal-time test LA position difference from
nominal.

• Image – Displays the real-time test image. Search result target graphic
overlays image.

• Plot – Displays a real-time plot. Difference dot plot is shown in green.

82 Diagnostics Clarios Service Manual

 Controls
See “Manual Color Bar Locate” on page 75 for more information about
using the search arrows.

Message Box
Messages describing actions taken at this screen, such as “Tracking
Swatch,” display in the message box.

Tracking Swatch

7.3 System Tests

If the On-Press scanner is giving incorrect readings, there may be errors in
the settings for the servo, camera, or measurement systems. To determine
where errors might be occurring, the operator can run the system tests.

This option is available to both operator and installer. However, due to

limitations of the On-Press, the operator can select an On-Press unit for
testing, but not individual scanners.
1. Touch the System Tests icon to display the System Tests dialog.
Head 1 Test Results Head 2 Test Results

On-Press
Selections
window
Details
or
Ellipsis
buttons

Test
button

Figure 7.12: System Tests Dialog

Clarios Service Manual Diagnostics 83

 2. Touch the icon in the On-Press Selections window for the selected
On-Press.

Note:The operator can select only one On-Press unit at a time.

The Head1 and Head2 test results sections display the test items and
the results for scanner heads 1 and 2.
If the On-Press selected is a one-head unit, the result area for the
unused head is blank.
3. Touch the Test button to start the tests. A decision dialog displays. The
message asks: “Scanning must be stopped to continue with this
operation. Do you want to continue?”.

WARNING: Undertaking this diagnostic will stop Clarios from

controlling color on the press.

4. Touch the Yes button. A confirmation dialog appears with a warning

statement: “Attention - Testing will cause scanner head(s) to move out
over web (as long as the press speed is fast enough). Continue?”.

5. Touch the Yes button to continue the tests. Selecting No cancels the
tests.
6. Clarios automatically tests the following:
> servo system
> camera system
> measurement system
> camera images - include black and white images

84 Diagnostics Clarios Service Manual

 Test Results
After the tests are done, results are displayed as:
• Passed – Indicated by a large green check mark.
• Failed – Indicated by a red check mark (only when the result error
code is 0).
• Test Skipped – Indicated by an empty check box.
• Numeric Readings – Shown in the respective fields.
• Details – Pop-up dialog box (System Test Report) shows test details.

Note: To display a pop-up box, touch the ellipsis or details button for
servo, camera, or measurement systems.

Figure 7.13: System Test Report - Servo Test

Note: If any system fails, report it to GMI Customer Service.

Control Buttons
• Test – Touch this button to start the tests.
• Cancel – Touch this button to cancel the operation while doing the
system test.
• Close – Touch this button to close the System Tests dialog.

Clarios Service Manual Diagnostics 85

7.4 Head Target Alignment
This option allows the operator locate specific swatches of a color bar and
to perform tests on the selected swatch to determine its LC alignment
difference and suggest a new value.
1. Touch the Head Target Alignment icon to display the Diagnostics
view.
2. At the Diagnostics view, touch the camera icon and the Head Target
Alignment dialog displays.

Color Bar
Images

Controls

Figure 7.14: Head Target Alignment Dialog

3. Use the arrows in the Controls section to perform a search.

4. When the Done button is touched, a Diagnostics dialog appears
asking: “Execute Test Procedure On Target In Image #1?”.

86 Diagnostics Clarios Service Manual

 5. Touch Yes to execute the test procedure on the target and the Color
Bar Images section of the Head Target Alignment dialog changes to a
Head Target Alignment section.

Figure 7.15: Head Target Alignment Section

Head Target Alignment Section

This section shows the numeric values and graphical representations of
the following parameters:
• LC Alignment – Contains two windows:
> Current: Current system configuration value.
> Suggested: Suggested configuration value when test completes.

• Test Index – Real-time test pass count.

• Test LC – Real-time test head alignment value.

• Density – Real-time test density measurement.
• Reflectance – Real-time test reflectance measurement.
• Standard Deviation – Real-time standard deviation.

Clarios Service Manual Diagnostics 87

 • Image - Real-time test image. The search result target graphic
overlays the image.

• Plot – Real-time plot.

> Plot bottom scale adjusts depending on 4-inch or 8-inch probe
head.
> Density line plot is in green.
> Reflectance line plot is in yellow.
> Standard deviation line plot is in magenta.

Controls
See “Manual Color Bar Locate” on page 75 for more information about
using the search arrows.

Message Box
Messages describing actions taken at this screen, such as “Searching
Right,” display in the message box.

88 Diagnostics Clarios Service Manual

7.5 Web Watch
This option allows the installer to watch, collect, and analyze the printing of
the press and the measurement characteristics of the Clarios system.
1. Touch the Web Watch icon to display the Diagnostics view.
2. At the Diagnostics View, touch the camera icon and the Web Watch
dialog displays.
Color Bar
Setup
Section Black
bracket
Color Bar
Layout
Green
window
bracket

Color Bar
Images
Section
camera image
appears here

swatch location on
ruler displays here
Manual Color
Search
Section

arrows

message
box

Figure 7.16: Web Watch Dialog - Initial

3. Search for a color bar by following the instructions in “Manual Color
Bar Locate” on page 75.
4. When the Done button is touched, a yellow box displays in the center
of the Color Bar Images Section of the dialog.
5. Touch the yellow box and the Web Watch decision dialog appears.

6. The message asks: “Execute Test Procedure On Target In Image #1?”.

Clarios Service Manual Diagnostics 89

 7. Touch Yes to execute the test procedure on the target and the Web
Watch dialog displays.
8. The Web Watch dialog is made up of the following sections:
> Web Watch Control
> Web Watch Results
> 4 Plot Displays
> Plot Graph Area

Web
Watch
Results

Plot
4 Plot Graph
Displays Area

Web
Watch
Control

Figure 7.17: Web Watch Dialog - After Test

90 Diagnostics Clarios Service Manual

 Web Watch Control
This section of the dialog contains the following subsections:
• Up and Down arrows – During the standard Watch and/or Measure,
these buttons adjust the LC position value. While in Adjust ENC mode,
these buttons adjust the encoder remainer values by 0.0001. While in
Adjust LC mode, these buttons adjust the LC target alignment value by
0.010 cm (0.004 in).

• Left and Right arrows – During standard Watch and/or Measure,

these buttons adjust the LA position value by 0.010 cm (0.004 in).
While Track LA is active, these buttons adjust the LA position value by
0.40 cm (0.16 in), or one swatch.
• LA and LC - Windows display the values at the time the sample was
taken.

• Watch – This option toggles the On-Press camera On and Off. The
camera takes an image of the current head position. The LA and LC
values at this position are displayed in the windows.

• Measure –This option toggles the On-Press On and Off in the same
way as the Watch option toggles the camera. The On-Press takes a
measurement along with the camera image at the current head
position. The LA and LC values at this position are displayed in the
windows. This option is only available when Watch is active.
• Track LA - This option toggles the On-Press from automatically
adjusting the LA position based on the camera search results of the
image. If the image search failed, no LA position adjustment is made.
This provides the operator with the ability to watch a swatch, without
manually adjusting the LA position, during a normal web weave
movement. This option is available only when Watch is active.

Clarios Service Manual Diagnostics 91

 • Adjust LC – This option toggles the On-Press from adjusting its
measurement location based on the image search results. When Off,
the measurement is made at the LC position displayed in the LC
window. When On, the measurement LC position is adjusted based on
the image search results. For proper measurement results, this option
should be active. This option is available only when Measure is active.
• A/B – This option toggles the Host plot displays between drawing a
single plot line for all samples or drawing separate lines for even and
odd impression samples.
• Capture – This option toggles the capture feature On and Off. This
feature stores each sample that will either be saved or displayed later.
If, during this Web Watch session, the capture option has been turned
on and then off, a prompt to reset to zero will be displayed when the
option is turned on again.
The window below this button displays the captured sample count.
This option is only available when Watch is active.

Options drop-down menu

Figure 7.18: Capture/Review Buttons

• Review – This option toggles the captured samples review mode
which allows the operator to scroll through the captured samples and
see the values in the appropriate windows. The window below this
button displays the currently displayed sample as well as the total
number of captured samples. This option is available when Watch is
NOT active and when there are results which have been captured.

92 Diagnostics Clarios Service Manual

 • Options – This option has a drop-down menu of additional Web Watch
operations: Statistics, Encoder, Load, and Save.
> Statistics: Toggles the display of additional statistics on the
captured samples.

Figure 7.19: Statistics Displayed

> Encoder: Toggles the display of the samples encoder index values
used for the camera, measure and adjustment operations.

Figure 7.20: Encoder Displayed

Clarios Service Manual Diagnostics 93

 > Load: – Provides the means to load previously captured Web
Watch results for display from either the Host floppy drive A, CD
drive D, or the Color Manager.
Select the Load option and the Web Watch - Open dialog displays.

Figure 7.21: Web Watch - Open Dialog

Select a date, touch the OK button, and the data changes in the Plot
display area.
> Save:– Provides the means to save the captured Web Watch
results to either a floppy drive A, CD drive D, or the Color Manager.
• Cancel – This option allows the operator to exit the Web Watch view or
return to the color bar view to select another location.
• Message Box – Messages describing actions taken at this screen,
such as “Watching Swatch,” display in the message dox.

94 Diagnostics Clarios Service Manual

 Web Watch Results
This section of the dialog box contains the following subsections:
• Press – The Press dialog displays the current press speed in FPM, the
impression count, and the encoder value at the time the sample was
taken, as displayed in the LA and LC boxes (see below).
> Adjust ENC. button – This button toggles the ability to use the Up
and Down Arrow buttons to adjust the current encoder value.
> The Up and Down Arrow buttons adjust the remainder by one.
> The Page Up and Page Down Arrow buttons adjust the integer
value by one.
If the encoder value is not correct, the image will appear to scroll up or
down in the display window.

• Camera – The Camera dialog displays the image search results for LA
and LC, the search time in milliseconds, and the current LC target
alignment value at the at the time the sample was taken. LA is the
location across the web, LC is the location at the center of the web.
> Adjust LC button – This button toggles the ability to use the Up
and Down Arrow buttons to adjust the LC target alignment value
being used during the measurement. This provides a means of
visually testing for the proper alignment value as well as testing the
results of different values.

Clarios Service Manual Diagnostics 95

 • Measure – The Measure dialog displays the sample measurements
results in density and Lab.

> Reflectance button – This button toggles the display of the

sample measurement results in a reflectance curve.
> Compare button – This button toggles the reflectance display to
refresh with each sample or to overwrite the current sample.
Overwriting provides a quick comparison of similar measurements.

Reflectance
data

Figure 7.22: Data Display Area Showing Reflectance Data

• Web – The Web dialog shows a miniature of the web with the section
being displayed on the screen, enclosed in a small red box.

section of web
displayed

96 Diagnostics Clarios Service Manual

 Plot Displays
There are four plot displays. Each can be individually selected to display
any of the available options.

Figure 7.23: Plot Display buttons

Available options include:

K Plots the measurement “K” density results

C Plots the measurement “C” density results

M Plots the measurement “M” density results

Y Plots the measurement “Y” density results

L Plots the measurement “L” Lab results

a Plots the measurement “a” Lab results

b Plots the measurement “b” Lab results

E Plots the measurement “E” Delta E results

LA Plots the measurement LA search results

LC Plots the measurement LC search results

FPM Plots the press speed

When a plot mode is selected, the current samples value is used as the
plots nominal (center line) value. This value may be changed at any time
by touching the plot’s nominal value box and entering a value.

A zoom feature is available by touching anywhere within the four plots

graph area. When selected, Plot #1 is zoomed to fill the area of all four
plots. The values plotted may be selected by selecting the appropriate
option button for Plot #1. Touching anywhere within the plot area restores
the display to all four plots.

Clarios Service Manual Diagnostics 97

7.6 Color Compliance Check
This option allows the installer to perform a color compliance check, which
is an automated process used to verify that the scanner conforms to color
standards Status T or Status E. The process requires a custom color
standard and the values for that standard, which are listed in an
accompanying folder.

Before Beginning the Procedure

• The color standard must be installed (see below).
• The On-Press unit must be on.
• All scanning must be stopped.
• A form must be loaded in Clarios. On the Clarios workstation monitor,
choose the form for the scan head that is to be checked (top or
bottom).
• The On-Press module calibration assemblies must be clean and free
of contaminants.

Refer to Service Note 352 and inspect the type of calibration plaque
mounting. There will be a special procedure to check the color
conformance for these systems. The customer is expecting high
compliance to the calibration standard for inter-instrument agreement
between Clarios systems.

Install the Color Standard

1. Turn off power to the On-Press unit using the external enclosure power
switch.
2. Move the scan head out along the rail to allow access to the calibration
assembly.
3. Clean the calibration plaques. Wipe the plaques with a clean, soft cloth
dampened with alcohol or a mild cleanser (do not use a dry cloth or
abrasive cleaner). Be sure the plaque looks white, with no visible
defects or residues, especially in the middle of the square. There may
be chips at the edges, but not in the center of the plaque.
4. Verify that the serial number on the color standard matches the serial
number on the color standard card.
5. Slide the color standard under the spring clip on the calibration
assembly.
Note: It does not matter which direction the color standard card is
inserted under the clip, but it is best to install it with the serial
number label to the outside. This prevents the spring clip from
scraping off the label or marring the printed serial number on
the label.

98 Diagnostics Clarios Service Manual

 6. Move the scan head back to the home position.
7. Turn on power to the On-Press unit.

1234567890

Figure 7.24: Example GMI Color Standard

Start Color Compliance Check Procedure

1. At the Diagnostics view, touch the camera icon and the Diagnostics
Decision dialog displays. The message asks:” Scanning must be
stopped to continue with this operation. Do you want to continue?”.

2. Touch the Yes button to continue and the Color Compliance Check
Procedure dialog #1 displays.

Figure 7.25: Color Compliance Check Procedure Dialog #1

3. This dialog box asks “If this is the incorrect head, push No button
below and then select the desired Form.”

Clarios Service Manual Diagnostics 99

 4. If the five instructions are satisfied, touch the Yes button and the Color
Compliance Check Procedure Dialog # 2 displays.

Figure 7.26: Color Compliance Check Procedure Dialog # 2

100 Diagnostics Clarios Service Manual

 Entering Color Standard Values
1. Enter your color standard's serial number and the density values for
white, black, cyan, magenta, and yellow swatches and for the
uncertainties for each swatch. These numbers are listed on the label
inside your color standard's folder.
2. By default, all values are set to zero (0). Touch a window and the
numeric keypad appears. Enter the number by touching the number
keys and then press . Repeat until all the values from the card are
entered. When finished, touch the Done button.
3. You are prompted to confirm that you want to use the values as
entered. If you click No or Cancel, you return to the input screen.
Change the values as required, then click Done.
4. When you click Yes, the procedure begins automatically. The status of
the check is displayed at the bottom of the screen.

Figure 7.27: Check Status Message

Note: The density values for the standard need to be entered only the
first time the check is performed. But if you have more than one
standard (recommended), the values need to be entered again
each time you change standards. Always check the density
values on the screen against the values printed on the label in
the red folder.

Clarios Service Manual Diagnostics 101

 Color Compliance Check Results
When the check is complete, one of these messages is displayed:
• On-Press Head Complies with Color Standard:
The test passed; all values are within tolerance for the standard. Click
No when prompted to repeat the test. Remove the color standard from
the On-Press calibration assembly and resume Clarios operation.
• On-Press Head Does Not Comply with Color Standard:
The test failed because one or more of the values was outside the
tolerance for the standard. When prompted, run the test again to verify
the results. If repeated failures occur, consider these items:
> Inspect the swatches on the standard. There should be no
scratches, stains, fingerprints, or smudges. If there are problems
with the swatches, the standard should be replaced. A clean, dry,
white cotton cloth should be used to lightly wipe the standard. Use
no cleaning agents nor other solvents on this standard.
> Check the expiration date on the standard. This expiration date is
one year from the date the standard was shipped. The standard
may measure correctly after this date, but GMI recommends that
the standard be replaced after this date.
> Check the standard with another densitometer calibrated to Status
T (or Status E). Be sure the device is calibrated according the
manufacturer's procedure and calibration standard. The values
read on the densitometer should be with 0.02 or 2% of the stated
values for the Clarios standard.
If these items indicate the scan head does not comply with the
standard's values, then contact GMI Customer Service. The content of
the COLORSTD.LOG file from the Color Manager may be helpful
when talking with GMI.
• Color Standard Check Aborted:
The test was terminated because the press speed was too slow, the
wrong scan head was selected, no color standard was installed in the
calibration assembly, or the On-Press unit was not online. Correct the
problem, then begin the test again.

After the Check

• When the color compliance check is finished, turn off power to the
On-Press unit and remove the color standard from the calibration
assembly. Put the standard and its folder in their case and store in a
safe place. Turn on power to the On-Press unit.
• Test log data for the color compliance check is recorded in a text file
named COLORSTD.LOG on the Color Manager. This log is a text file
with test results. It may be printed as verification that the Clarios
system is providing accurate measurements using the Status T or
Status E filter set per ISO 5-3 and ANSI CGATS.5-1993.

102 Diagnostics Clarios Service Manual

 Revision History
Section/
Revision Revised
Version Page Revision Description
Date By
Numbers

4/1/2010 SW A All Initial release.

Clarios Service Manual Revision History 103

 This page is intentionally blank.

104 Revision History Clarios Service Manual

 Index
A
A/B .................................................................................................................................... 92
adjust LC ......................................................................................................................... 92
allow alphanumeric form numbers .............................................................................. 19
allow automatic form numbers ..................................................................................... 19
allow automatic switch to salable scan ....................................................................... 19
arrow buttons .................................................................................................................. 78
left or right ................................................................................................................. 78
B
button
Adjust LC .................................................................................................................. 95
Compare ................................................................................................................... 96
Jump .......................................................................................................................... 79
Reflectance .............................................................................................................. 96
C
calibration slide cover .................................................................................................... 67
cancel ............................................................................................................................... 94
capture ............................................................................................................................. 92
Clarios computer
turning off .................................................................................................................. 12
Clarios Server computer ................................................................................................. 5
reset ........................................................................................................................... 11
Clarios system .................................................................................................................. 3
Clarios workstation .......................................................................................................... 5
Clarios workstation computer ....................................................................................... 59
clean calibration plaque ................................................................................................ 56
clean camera and flash ................................................................................................. 55
clean probe head ........................................................................................................... 53
clean spectrophotometer .............................................................................................. 54
cleaning Clarios probe head and calibration plaque ................................................ 49
color bar ........................................................................................................................... 48
configuration ............................................................................................................. 42
configuration icon ..............................................................................................42, 47
import ........................................................................................................................ 43
manual view ............................................................................................................. 75
remove ...................................................................................................................... 43
setup .......................................................................................................................... 45
types .......................................................................................................................... 46
Color Bar menu .............................................................................................................. 47
color compliance check ................................................................................................. 98
Color Manager .................................................................................................................. 5
computer
Clarios workstation .................................................................................................... 6
Color Manager ........................................................................................................... 8
computer replacement
Clarios Server .......................................................................................................... 61
Clarios workstation .................................................................................................. 60

Clarios Service Manual 105

 On-Press ................................................................................................................... 62
control and process limits ............................................................................................. 22
D
default color symbol ....................................................................................................... 39
default tolerance ............................................................................................................. 38
Diagnostics menu
manual color bar view ............................................................................................. 75
Diagnostics view ............................................................................................................ 75
display color .................................................................................................................... 36
display options ................................................................................................................ 16
E
enclosure door ................................................................................................................ 13
encoder ............................................................................................................................ 93
exit the program ............................................................................................................. 12
F
filter ................................................................................................................................... 37
H
head target alignment ................................................................................................... 86
hide ................................................................................................................................... 16
high and low value for % in tolerance display ........................................................... 20
I
icon
Head Target Alignment .......................................................................................... 86
Locate Fixture Center ............................................................................................. 81
Manual Color Bar Locate ....................................................................................... 75
System Tests ........................................................................................................... 83
Web Watch ............................................................................................................... 89
icons
camera ................................................................................................................75, 89
color bar configuration ......................................................................................42, 47
ink manufacturers .................................................................................................... 30
ink types .................................................................................................................... 35
paper classes ........................................................................................................... 29
paper types ............................................................................................................... 31
password .................................................................................................................. 24
preferences .............................................................................................................. 19
sampling rules .......................................................................................................... 26
tolerance groups ...................................................................................................... 21
user selections ......................................................................................................... 17
idler and measure rollers .............................................................................................. 69
importing or deleting color bar ..................................................................................... 48
impressions between report sample prompt ............................................................. 27
ink manufacturers ....................................................................................................30, 36
Ink Manufacturers icon .................................................................................................. 30
ink name .......................................................................................................................... 36
ink suppliers
add name .................................................................................................................. 30

106 Clarios Service Manual

 ink type ............................................................................................................................ 35
add ............................................................................................................................. 36
description ................................................................................................................ 36
duplicate .................................................................................................................... 41
icon ............................................................................................................................ 35
remove ...................................................................................................................... 41
select target .............................................................................................................. 39
install color standard ..................................................................................................... 98
L
LA and LC ....................................................................................................................... 91
LC alignment
current and suggested ............................................................................................ 87
Left and Right arrows .................................................................................................... 91
limits ................................................................................................................................. 21
process and control ................................................................................................. 21
tolerance rules ......................................................................................................... 21
load ................................................................................................................................... 94
locate fixture center ....................................................................................................... 81
M
maintenance ................................................................................................................... 49
suspended On-Press units .................................................................................... 57
manual color bar view ................................................................................................... 75
measure .....................................................................................................................91, 96
message box .................................................................................................................. 94
N
network connections ........................................................................................................ 8
numerics .......................................................................................................................... 16
O
On ..................................................................................................................................... 62
On-Press
computer replacement ............................................................................................ 62
maintenance of suspended units .......................................................................... 57
powering down ......................................................................................................... 13
scanner ....................................................................................................................... 5
options ............................................................................................................................. 93
overhead frame and On-Press unit ............................................................................. 57
overview of Clarios probe head ................................................................................... 49
P
paper class ...................................................................................................................... 29
icon ............................................................................................................................ 29
names ........................................................................................................................ 29
paper type ....................................................................................................................... 31
adding ........................................................................................................................ 32
duplicate .................................................................................................................... 34
icon ............................................................................................................................ 31
manufacturer ............................................................................................................ 32
name .......................................................................................................................... 32

Clarios Service Manual 107

 remove ...................................................................................................................... 34
target values ............................................................................................................. 33
weight ........................................................................................................................ 32
Password ......................................................................................................................... 18
password ......................................................................................................................... 24
icon ............................................................................................................................ 24
protected ................................................................................................................... 18
setting user policy rights ......................................................................................... 25
user selections ......................................................................................................... 74
PIT
high ............................................................................................................................ 20
low .............................................................................................................................. 20
position encoders ............................................................................................................. 5
powering the system components ................................................................................. 9
preferences ..................................................................................................................... 19
press event sensors ........................................................................................................ 5
press speed display ....................................................................................................... 19
Primary types .................................................................................................................. 46
probe head and calibration plaque cleaning kit supplies ......................................... 50
PSI board ........................................................................................................................ 66
Q
quadrature encoder assembly ..................................................................................... 65
R
remove probe head ....................................................................................................... 51
replacement parts .......................................................................................................... 59
review ............................................................................................................................... 92
roller guards .................................................................................................................... 68
S
Sample Level 1 FPM ..................................................................................................... 26
Sample Level 2 FPM ..................................................................................................... 26
Sampling ......................................................................................................................... 28
sampling rule .................................................................................................................. 26
add ............................................................................................................................. 27
duplicate .................................................................................................................... 28
icon ............................................................................................................................ 26
name .......................................................................................................................... 27
remove ...................................................................................................................... 28
save .................................................................................................................................. 94
scan head replacement ................................................................................................. 64
scan head replacing ...................................................................................................... 64
Secondary types ............................................................................................................ 46
servo drive assembly ..................................................................................................... 70
setting
security levels .......................................................................................................... 25
user policy rights ...................................................................................................... 25
show ................................................................................................................................. 16
speed levels .................................................................................................................... 27
statistics ........................................................................................................................... 93

108 Clarios Service Manual

 subtract paper from all densities ................................................................................. 19
swatch type ..................................................................................................................... 22
system tests .................................................................................................................... 83
T
test probe heads ............................................................................................................ 56
tolerance group ........................................................................................................21, 37
add ............................................................................................................................. 22
duplicate .................................................................................................................... 23
name .......................................................................................................................... 22
remove ...................................................................................................................... 23
tolerance limits ............................................................................................................... 16
torque specifications ...................................................................................................... 72
track LA ........................................................................................................................... 91
U
units .................................................................................................................................. 16
up and down ................................................................................................................... 78
Up and Down arrows ..................................................................................................... 91
user selections icons ..................................................................................................... 17
Utility view
configuration tab ...................................................................................................... 15
W
warnings ......................................................................................................................... vii
watch ................................................................................................................................ 91
web ................................................................................................................................... 96
web watch ....................................................................................................................... 89
Windows XP
shutting down Clarios workstation ........................................................................ 12

Clarios Service Manual 109

110 Clarios Service Manual