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Section I: Imagesetter

Diagnostics

3-35

DSP/Plate

Selecting DSP displays a dialog box that shows the current Plate/DSP parameters
stored in the imagesetter. These parameters are in DEC EEPROM.  The software
retrieves them from EEPROM upon entering this menu selection.  New values are
written to the imagesetter by typing in a new value in the appropriate parameter.
The DSP values are achieved after running the carriage align test.
.

* System dependent

Variable

Media

 Parameter

Plate

(3-5)

narr

Plate

(3-5)

med

Plate

(3-5)
wide

Plate

(6-8)

narr

Plate

(6-8)

med

Plate

(6-8)
wide

Plate

(9-12)

narr

Plate

(9-12)

wide

DSP

#

DSP

Offset

DSP

Data

S-Feed Curr

24

(0x50)

24

(0x53)

24

(0x56)

24

(0x59)

24

(0x5C)

24

(0x5F)

32

(0xB2)

32

(0xB5)

0

0x3C

0x*

T-Comp Curr

24

(0x51)

24

(0x54)

24

(0x57)

24

(0x5A)

24

(0x5D)

24

(0x60

28

(0xB3)

28

(0xB6)

1

0x3D

0x *

T-Comp Spd

6

(0x52)

6

(0x55)

6

(0x58)

6

(0x5B)

6

(0x5E)

6

(0x61)

6

(0xB4)

6

(0xB7)

2

0x3E

0x *

Nip Cycle

61

(0x44)

41

(0x46)

41

(0x48)

3

0x3F

0x *

Nip Incr

60

(0x45)

40

(0x47)

40

(0x49)

4

0x4D

0x *

BrOfEarly

50

(0x4A)

40

(0x4B)

46

(0x4C)

5

0x4E

0x *

BrOn Delay

1

(0x4F)

1

(0x62)

1

(0x63)

6

0xFF

0xFFFF

TUStartDly-Pl

0

(0x4D)

0xFF

0xFFFF

IfdCstDly-Pl

10

(0x4E)

S-Feed Spd-Pl

*

(0x2D)

12 Mil Plate

Offset

Value

T-UpStepDurSh

(0xB9)

46

T-UpStepDurLo

(0xBA)

60

T-DnStepDurSh

(0xBB

48

T-DnStepDurSh

(0xBC)

60

T-DnStartPtSh

(0xBD)

95

T-DnStartPtSh

(oxBE)

225

T-FeedCurLim

(oxBF)

50

Summary of Contents for Avantra 36/44

Page 1: ...The Avantra 36 44 Service Manual Part Number 580078 0002 ...

Page 2: ...produce or disclose the document any part thereof any information contained therein or any physical article or device or to practice any method or process except by written permission from or written agreement with Agfa Division Bayer Corporation COPYRIGHT 1996 1997 Agfa Division Bayer Corporation Prepared by Customer Documentation 200 Ballardvale Street Wilmington MA 01887 Printed in the U S A 58...

Page 3: ...tion xx GLOSSARY OF ACRONYMS Glossary of Acronyms xxiii SECTION 1 IMAGESETTER Chapter 1 Imagesetter Installation Procedures Introduction 1 1 Customer Pre site Checklist 1 1 Service Engineer Installation Procedure 1 4 Pre installation Checks 1 4 Unpacking the Imagesetter 1 5 Unlocking and Installing the Imagesetter 1 13 Checking the System 1 22 Customer Application Training 1 24 Chapter 2 Imagesett...

Page 4: ...o DEC Interface 2 12 Laser Driver Module LDM 2 13 Power Supply 2 14 Additional Voltages 2 14 Power Distribution 2 14 Power Good 2 14 Optical System Overview 2 15 Spot Generation Module 2 16 Laser Diode Mount 2 17 Polarizer 2 17 Spot Size Changer 2 17 Spot Forming Lens 2 17 Weak Lens 2 18 Beam Compressor 2 18 Spin Motor Module 2 18 Spin Motor 2 19 Mirror 2 19 Encoder 2 19 Linear Carriage Transport ...

Page 5: ...ations 2 38 Humidity Low Indicator 2 38 Water Supply Empty Alert 2 38 Chapter 3 Imagesetter Diagnostics and Vacuum System Troubleshooting Guide Introduction 3 1 Power up Boot Diagnostics 3 2 Power up Boot Diagnostics Overview 3 2 Power up Boot Sequence 3 3 Error Reporting 3 5 Automatic Dial out Feature 3 11 Boot Error Codes 3 13 OCP Run Time Application Errors 3 15 Avantra Diagnostic Program PC 3 ...

Page 6: ...or 4 22 Take up Media Present Detector 4 23 Supply Jam and Media Present Sensors 4 24 Electrical Removal Replacement Procedures 4 25 Digital Engine Controller DEC PCB 4 25 Carriage Sensor Driver CSDM PCB 4 28 Operator Control Panel Assembly 4 30 The Supply and Take Up Sensor Driver Modules PCB SDMs 4 32 Power Supply 4 34 Main Power Switch 4 36 Exhaust Fan 4 38 Intake Fan 4 39 Carriage Drive Remova...

Page 7: ...ine BOL Alignment Procedure 5 2 Exposure Adjustment Procedure 5 4 Carriage Home Position Alignment Procedure 5 5 Focus Alignment 5 7 System Leveling Procedure 5 10 Voltage Check Procedure 5 11 Pulse Width Modulation PWM Adjustment Procedure 5 11 Carriage Encoder Alignment Procedure 5 14 Supply Motor Offset Alignment Procedure 5 14 Take up Cassette Clutch Adjustment Procedure 5 16 Feed Motor Calibr...

Page 8: ...ng the Solid Stops 1 17 Setting up the DEC to Bridge Buffer Interface 1 18 Attaching the Ground Wires 1 21 Chapter 2 Bridge Functional Analysis Introduction 2 1 Chapter 3 Bridge Debugger Diagnostic Tool Introduction 3 1 Setting Up the Debugger Port 3 2 Bridge Debugger User Interface 3 3 Terminal Code Identifiers 3 3 Bridge Unlock Sequence 3 3 Bridge States 3 4 Bridge State Responses 3 5 Bridge Err...

Page 9: ...res 1 2 Unpacking the Buffer 1 2 Unlocking the Buffer 1 6 Installing the Buffer to the Imagesetter 1 10 Aligning the Buffer Carriage 1 19 Chapter 2 Buffer Component Removal Replacement Introduction 2 1 Buffer Home and Buffer Processor Sensors 2 2 Buffer Purchase Sensor 2 3 Buffer Carriage Drive Motor 2 4 Buffer Roller Driver Motor 2 5 Appendix A Spare Parts Index SECTION IV ON LINE PROCESSOR Chapt...

Page 10: ...Attaching the OLP to the Buffer 1 20 Attaching the Panels and Covers 1 24 Chapter 2 OLP Functional Analysis Introduction 2 1 Description of OLP Boot up Procedures 2 2 OLP Standby Mode 2 2 Idle Mode 2 2 Ready Mode 2 2 Operate Mode 2 2 The OLP Jog Function 2 3 Electronics 2 3 The LUTH Computer Board LCB 2 3 The LUTH Power Board LPB 2 6 The LUTH Motor Board LMB 2 8 The Agfa Terminal Board ATB 2 8 Sen...

Page 11: ... 2 Checking Sensor Operation 4 2 Checking Operation of the LCB 4 3 Checking the Battery 4 4 Setting the Jumpers 4 5 Calibrating Jumper Settings 4 6 LUTH Motor Control Board LMB 24V DC P N 5202Y000100 4 7 LUTH Motor Control Board LMB 180V DC P N 5203Y4000200 4 11 Replenishment Pumps Calibration 4 12 Troubleshooting 4 14 The Service Program 4 14 Service Program Codes 4 16 How to Use the Repair Metho...

Page 12: ...es 1 3 The Mounting Plate and Boom 1 3 Mounting the Head 1 7 Chapter 2 Crane Component Removal Replacement Introduction 2 1 Crane Removal Replacement Procedures 2 2 Crane On Off Switch 2 2 Crane Motor 2 7 Crane Slack Safety Switch 2 9 Crane Cable 2 10 Appendix A Spare Parts Index ...

Page 13: ...d crane Warnings Cautions and Notes The terms WARNING CAUTION and NOTE have specific meanings in this manual A WARNING advises against certain actions or situations that could result in personal injury or death A Caution advises against actions or situations that could damage equip ment produce inaccuracies or invalidate a procedure although direct per sonal injury is unlikely A Note provides usef...

Page 14: ... these safety rules Never look directly into the beam Never expose other persons to the laser beam Use caution with tools and other reflective surfaces to prevent laser reflec tion Keep the work area well lit Follow the assembly disassembly procedures precisely No short cuts These procedures are in the Imagesetter section Section I Chapter 4 Imagesetter Component Removal Replacement Procedures Nev...

Page 15: ... class of laser radiation dur ing operation and maintenance DANGER LASER RADIATION WHEN OPEN AVOID DIRECT EXPOSURE TO BEAM PELIGRO RADIACION LASER CUANDO SE ABRA EVITE LA EXPOSICION DIRECTA DEL HAZ VORSICHT LASERSTRAHLUNG TRITT AUS WENN DECKEL GEOFFNET IST NICHT DEM STRAHL AUSSETZEN DANGER RAYONNEMENT LASER A L OUVERTURE EVITER TOUTE EXPOSITION DIRECTE AU RAYON CLASS 1 LASER LASER KLASSE 1 ...

Page 16: ...system operate using the following safeguards Do not operate the OLP if it is not level Be careful not to touch the dryer when the top cover is removed The dryer gets hot during operation and should be allowed to cool before ser vicing Agfa Division certifies that this product conforms to all applicable provisions of 21 CFR Subchapter J in effect as of the date of manufacture Wilmington MA 01887 a...

Page 17: ... with the internal workings of an image processor Refer to the Removal Replacement Procedures chapters present in each section before attempting to service the inside of an Avantra 36 44 imagesetter processor bridge buffer or crane NOTE The intent of the Removal Replacement Procedures chap ters in this manual are not to repair the units to the level of their individual components e g the chips on ...

Page 18: ...the imagesetter including physical electrical environmental and functional data Appendix B Spare Parts Index Section II Bridge Chapter 1 Bridge Installation Procedures Provides the information necessary for installing the internal bridge Chapter 2 Bridge Functional Analysis Provides an operational and functional overview of the Avantra s internal bridge Chapter 3 Bridge Debugger Diagnostic Tool De...

Page 19: ...alysis Provides an operational and functional overview of the Avantra s OLP including descriptions of the electronics boards and sensors Chapter 3 OLP Component Removal Replacement Provides the procedures for removing and replacing defective components within the Avantra OLP Chapter 4 OLP Preventive Maintenance Describes the procedures for inspecting and cleaning the Avantra buffer Appendix A Spec...

Page 20: ...n the engine at the same time Flex media automatically adjusts focus for the selected media thickness user definable media widths Advanced Features In addition to the advanced design features of the 20 25 the 36 44 has EasyLoad media handling which allows the convenient loading of large format supply cassettes Vacuum system which aids in keeping the media tight against the drum for optimum image q...

Page 21: ...lowing illustrations show the imagesetter with all the OLP options installed and attached The Avantra 36 44 imagesetter buffer and crane Imagesetter Crane Buffer On line Processor OLP The bridge Top cover Bridge Light shield 2 3 1 4 1 2 3 ...

Page 22: ... Standard ATB Agfa Terminal Board AT Attention Command AVDIAG Avantra Diagnostic Program BOL Beginning Of Line BCC Basic Confidence Check CSDM Carriage Sensor Driver Module DEC Digital Engine Controller DSP Digital Signal Processor DVM Digital Volt Meter FPGA Field Programmable Gate Array FRU Field Replaceable Unit ICS Image Control System LCB Luth Computer Board LCD Liquid Crystal Display LDD Las...

Page 23: ...cuit Board PLL Phase Lock Loop PWM Pulse Width Modulation RAM Read Access Memory RIP Raster Image Processor ROM Read Only Memory SDM Sensor Driver Module SGM Spot Generation Modules SPI Serial Peripheral Interface TSDM Take up Side Media Transport T U Take Up ...

Page 24: ...Section I Imagesetter ...

Page 25: ...g 1 2 Customer Pre site Checklist The customer should use the following pre site checklist to ensure that the intended installation site is properly prepared to receive and install the Avantra 36 44 image setter Power Requirements The customer must provide a separate isolated three wire 115 230 VAC grounded power line The wires can be run in conduit but the conduit cannot serve as a ground The rec...

Page 26: ...ifications for the imag esetter include Oper Temp 65 to 80 F 18 to 27 C Humidity 45 to 55 non condensing For absolute accuracy 70 F 3 21 C 2 Work Space The system should be located in an area that allows enough surrounding space to permit unrestricted air flow and service access Approximately three feet should be left on all sides No overhead lights should appear directly over the system The syste...

Page 27: ...s also highly recommended The phone line connector must be an RJ11C type connector Film Processor Requirements It is recommended that a customer producing color separations use a deep tank film processor An AGFA processor is preferred i e RAPILINE 44 OLP and P The processor must be able to handle media widths of 36inches or greater If a new processor is to be installed electrical requirements for ...

Page 28: ...strongly recom mended for viewing separation films produced on the Avantra 1 3 Service Engineer Installation Procedure The following four procedural steps must be performed sequentially by the Agfa service engineer 1 Agfa pre installation checks 2 System unpacking 3 System unlocking 4 System installation 5 Customer application training 1 3 1 Pre installation Checks This section contains a pre inst...

Page 29: ...ate in the location that the system will be installed Check for proper clearances around system as listed in Appendix A Specifications Cut the shipping straps holding the crate panels to the pallet Refer to Figure 1 2 2 Remove the top pad Refer to Figure 1 2 3 Remove the crossbars left and right at the top of the open crate Refer to Figure 1 2 4 Remove the two 2 bottom bolts on the front and back ...

Page 30: ...de Two crossbars 6 Remove the parts list and accessory box Refer to Figure 1 3 Put the acce sory box aside for the unlocking and installing procedures 7 Remove the three 3 bolts at each corner of the end supports Refer to Figure 1 3 The end supports hold the end plates in place 8 Remove the end plates one at each end Refer to Figure 1 3 and Figure 1 4 1 3 4 1 2 5 ...

Page 31: ...ng straps Accessory box End support bolts with washers Tool kit End plate Diaper 9 Cut the two 2 large tie wraps at the center channel front and back Refer to Figure 1 4 The bottom diaper should fall to the ground 10 Remove the bottom diaper by sliding it out from either side of the pallet Refer to Figure 1 4 2 1 3 4 7 5 6 ...

Page 32: ...er channel bolts on either end Refer to Figure 1 5 Allow only a small gap of 1 8 between the bolt heads and the beams WARNING Do not remove the outer channel bolts Doing so may result in the imagesetter falling off the jack screw see succeeding steps The two 2 end bolts hold the channel beams wood to the end channels metal The middle bolt holds the center channel do not remove this bolt until Step...

Page 33: ...el bolt End channel 12 Loosen the four 4 inner channel bolts left and right on the bottom of the end channels Refer to Figure 1 5 WARNING Do not remove the bolts 13 Remove the two 2 center channel bolts one on each side of the center channel Refer to Figure 1 5 The bolts hold the center channel to the pallet beam There are no bolts holding the center channel to the imagesetter frame Once the cente...

Page 34: ... left side See Chapter 4 Section 4 2 2 Top Middle and Bottom Front Panels 17 Working within the opened left end position the jack screw provided see Figure 1 1 in the access hole in the end cap located at the bottom of the frame Refer to Figure 1 7 18 Before lowering the jack screw to the floor position the jack screw plate so that its dimple is directly below the access hole Refer to Figure 1 7 C...

Page 35: ... unit begins to lift on the plate Raise the unit only an inch from the ground 20 Release the unit from the pallet by removing the two 2 outer bolts and their spring clips Refer to Figure 1 7 CAUTION Leave the door slightly ajar before lowering the unit Doing so prevents the door fom hitting the floor first 21 Lower the unit to the floor by turning the jack screw NOTE Use the breaker bar on the wre...

Page 36: ...he jack screw and plate for raising the imagesetter right side Pump Jack screw Electrical box Jack screw dimpled plate 25 Position the jack screw dimpled plate below the access hole and turn the jack screw until the unit begins to lift Refer to Figure 1 8 26 Release the unit from the pallet by removing the two 2 outer bolts and their spring clips Refer to Figure 1 7 27 Lower the unit to the ground...

Page 37: ... attaching the side plates to the platen and the brackets to the imagesetter frame Side plates Brackets The chafe tray is part of the imagesetter installation hardware The extension platen and related hardware are used when attaching the imagesetter to the buffer See Avantra 36 44 Buffer Service Manual Chapter 1 Steps 1 Remove the foam strips between the front panels and frames Refer to Figure 1 1...

Page 38: ...gure 1 10 Removing the packing materials from the front of the imagesetter Cardboard packing strips Foam packing strips 3 Remove the cardboard packing and the two 2 plastic inserts near the top of the imagesetter s back panel Refer to Figure 1 11 2 1 ...

Page 39: ... the imagesetter One of 2 plastic inserts Cardboard packing 4 With the top cover open remove the four 4 screws in the bridge tie down bracket red in the lower left and lower right corners of the bridge foot Refer to Figure 1 12 Reinsert the screws into the bridge holes once the bracket is removed 1 2 ...

Page 40: ...t in light mode To initiate light mode the imagesetter must first be turned on 5 Lift the bridge and the upper light shield 6 Remove the front top panel See Chapter 4 Section 4 2 2 Top Middle and Bottom Front Panels for removing the front panels 7 Locate the lower media transport Retainer Bracket black in the lower left of the exposed unit Remove the two 2 bracket hex screws Refer to Figure 1 13 1...

Page 41: ...ransport retainer bracket Transport retainer bracket Two bracket hex screws Supply tray 8 Locate the two upper media transport Retainer Brackets gray in the upper right and left of the exposed unit Refer to Figure 1 14 Remove the ship ping screw at the center of the bracket 3 1 2 ...

Page 42: ...one of two Shipping screw one of two between two lockdown screws 9 Locate the take up light shield in the center of the unit Refer to Figure 1 15 Remove the shield by unscrewing the three 3 locking knobs and pulling the shield straight out Figure 1 15 Removing the take up light shield Take up light shield Three shield locking knobs 1 2 1 2 ...

Page 43: ...and to each side of the exposed area Refer to Figure 1 16 Figure 1 16 Inserting the chafe tray Chafe tray Chafe tray hook 11 Replace the take up light shield Unlocking the Vacuum Pump 1 Open the right side door 2 Loosen the four hex screws on the orange tie down bracket that secures the vacuum pump 3 Remove the orange tie down bracket 2 1 ...

Page 44: ...ing them so that they rest outside of the lock slot Refer to Figure 1 17 The light shield on the left requires a twist toward the door to remove Pull the light shield on the right straight out NOTE When removing the light shield the interlock switch located above the shield see Figure 1 17 automatically shuts off the laser and spin motor Figure 1 17 Removing the light shields Light shield Interloc...

Page 45: ...e center stop 5 Power up the imagesetter which makes the flappers lift Remove the foam pads from the right hand side of the imagesetter Refer to Figure 1 18 6 When the carriage comes into the home position remove the foam from the left hand side of the system Refer to Figure 1 18 7 Shut off the imagesetter Replace the light shields left and right and close the left side cover 8 Turn the system on ...

Page 46: ...ection 3 Diagnostics for more detailed information Check engine configuration Check image focus parameters Check media parameters Check DSP parameters Check operator s control panel OCP user parameters Check firmware revision levels Check clear error log parameters Check operational statistics 4 After completing the above checks save the system parameter files listed below to the portable PC s har...

Page 47: ...a user guide 7 Using the PC Imager run an exposure array at each resolution Use the current density setting minus approximately 10 steps on the control panel for a starting density for the array This insures a density reading on both sides of the current density setting Measure the density at each resolution and adjust if necessary approximately 4 2 to 4 6D he he he he he he he he he he he he he h...

Page 48: ...assette into the system Procedures for clearing media and cutter jams O2 6K he O20M I46K h W2 M I 6X g 7 Y V 1 g J Y V g 7H he O2 N 6Xf J5heO2 3 1f 7HhW2 0M e N L e g W 0M f 1 e gW M g Le f W Yh 1e fW Y h e f7 Yhe g W Xh e e J H he gW X g e e 7 5hW2 f W Xg e e Hg W fW X f e eJ 5 gW 0M f W Y V Xf e e7 H f W hW Y eV X e e e g 7 5g W Yf V Xe e e g HgW h X e e g g7 1 g7 1 e e g g g e e g LhW g f e e g...

Page 49: ...ntenance routines Functionality of the control panel Daily operating procedures Defining cassette parameters Determining proper exposure settings Setting system defaults System error reporting and brief descriptions of possible solutions to error conditions which results in reduced numbers of unnecessary service calls ...

Page 50: ...ach Understanding the fundamental operation of the individual subsystems is a valuable aid to service personnel in diagnosing and troubleshooting system level problems The following topics are covered System Overview Electronics Overview Electronics Packaging System Architecture Digital Engine Controller DEC Operator Control Panel Micro controller OCP FLASHROM Liquid Crystal Display LCD Keypad OLP...

Page 51: ...ns Beam Compressor Spin Motor Module Spin Motor Mirror Encoder Linear Carriage Transport Overview Carriage Assembly Linear Bearing Guideway Carriage Home Position Sensor Inner Shrouds Vacuum System Media Transport System Overview Supply Side Mechanics Powered Media Take up Cassette Media Punch Clamp Assembly Take up Drive Assembly Media Cutter Assembly Supply Cassette Humidifier Sub Assembly Fan C...

Page 52: ... is no medium movement during the process After imaging the medium moves into a removable powered take up cassette The medium can now either be cut with the motorized cutter and removed for processing or the next job can be imaged and fed into the cassette The exposure source is a solid state laser diode 650nm that focuses to a spot size of 7 7 microns 30 mil at the medium surface with a maximum a...

Page 53: ...d control for the laser diode Two more PC boards reside within the imagesetter These boards provide driver sensor control for the Media Transport system called the Sensor Driver Modules SDM The two boards are identical with one controlling the supply side and the other controlling the take up side The OCP PC board plugs directly into the back of the touch screen display The OCP provides the electr...

Page 54: ...ring sensor arrays Video modulation Spot Polarizer and focus motors Saving restoring EEPROM parameters Setting up initializing imaging functions including stop start Motor bridge support 2 3 2 3 DSP Micro controller Diagnostic tests Handling SPI communication primitives Providing low pass filters Carriage servo velocity information Spinner servo loop Supplying servo loop 2 3 2 4 OCP Micro controll...

Page 55: ...tra 36 44 Service Manual 2 6 Functional Analysis 2 3 2 5 DEC K 1 FLASHROM Main DEC software 2 3 2 6 DSP FLASHROM DSP main program Correction tables 2 3 2 7 OCP FLASHROM OCP main program Control panel icons ...

Page 56: ...he system master the DEC directs the individual stepper motors sensors and or DSP servo loops Refer to the flowchart in Figure 2 2 Micro controller DEC Machine Parameters 1 Image Focus Parameters 2 Media Parameters 3 DSP PLATE FLASHROM 1 DEC K1 Software DSP Main Program Correction Tables Micro controller 1 OCP User Parameters 2 Cassette Parameters 3 Operational Statistics 1 OCP Main Program 2 Cont...

Page 57: ...vided into the following submodules Synchronous serial interface SPI Image control Asynchronous serial interface on line processor System sensor 5 x 6 matrix submodule Driver selection 2 5 Operator Control Panel The operator control panel module OCP is the system task master The OCP implemented with a micro controller gathers both APIS commands from a RIP and user commands from the keyboard Comman...

Page 58: ...ent in the OCP module 2 5 2 OCP FLASHROM The OCP FLASHROM contains the graphic display data for the control panel i e icons as well as the main OCP code The OCP module uses a 2M 512 x 8 ver sion of this ROM A serial communication link to a PC which can be remote or on site can update the FLASHROM FLASHROMS unlike UVPROMS can be electrically erased and re programmed This eliminates the need of phys...

Page 59: ...y clearing a column signal and reading the row to determine the active key stroke 2 5 5 OLP Bridge Interface Refer to Section IV On line Processor 2 5 6 Speaker Audio Interface The OCP module includes a beeper speaker The beeper speaker connects to a port on the OCP micro controller and can be activated under software control 2 6 Carriage Sensor Driver Module CSDM The CSDM is a PC Board that conne...

Page 60: ...tions on the opposite side of the system Refer to the SSDM and TSDM interconnect illustrations for the functions they support The SDMs perform several functions for the Media Transport system Provides a direct connection to the DEC through a ribbon cable and pro vides power and control of reads and writes of all devices connected to the SDMs Provides the necessary drive for all the media transport...

Page 61: ...he servo motors also pass through this header to the appropriate servo motor 2 7 1 1 Motor Drives The SDM has three basic types of motor drivers Stepper DC motor solenoid Servo 2 7 1 2 Sensors Each SDM supports twelve sensors configured in a 2 x 6 matrix The matrix is read directly by an 8 bit data port through a RS 423 type driver pair to the DEC The sensor matrix is similar to that of a keypad d...

Page 62: ...ons in laser cavity temper ature are reduced by the use of wideband active feedback This feedback loop compares the laser diode photodiode current with a reference current In order to keep the loop disturbance to a minimum when the laser diode is turned off a cur rent steering type feedback loop is used The laser diode is turned off by steering the loop current into a dummy laser which keeps the l...

Page 63: ... power to the diag nostic modem 2 9 2 Power Distribution A discrete wiring harness provides power from the power supply to the DEC PCB The signal cabling supplies power for isolated boards within the system This har ness will be included with the power supply as a complete field replaceable unit 2 9 3 Power Good The power supply generates a power good signal which is used as a reset within the sys...

Page 64: ...er one of four apertures resizes and shapes the beam Next the weak lens spot forming lens re focuses the beam to a small imaging spot The spin mirror on the shaft of the spin motor re directs the beam 95 degrees away from the spin axis and sweeps the imaging spot in a circular motion as the motor rotates at high speeds As the imag ing spot sweeps across the inside of the drum the entire optical sy...

Page 65: ... on which the following mount Laser diode module Polarizer sensor Spot size changer sensor Spot forming lens Weak focus lens sensor Beam compression motor sensor Figure 2 7 Spot generation module Polarizer sensor Beam compressor motor Beam compression sensor Weak lens motor Spot size changer Spot forming lens Laser diode mount Polarizer wheel and motor Focus sensor Spot size sensor 11 Aperture whe...

Page 66: ...in the glass A home position hole passes through an optical sensor to signal that the polarizer is at the home position The polarizer motor and sensor are field replaceable 2 11 3 Spot Size Changer The spot size changer consists of an aperture wheel that is rotated in the laser beams path by a stepper motor The changer alters the size of the focused spot at each addressability Refer to Figure 2 7 ...

Page 67: ...l focus adjustment The software to automatically adjust focus for dif ferent media thicknesses is optional 2 11 6 Beam Compressor The beam compressor mechanisms consist of a lens sensor and motor The lens is moved in front of the laser diode only at 1200 DPI This occurs because of the larger dot 20 microns which requires more laser output at 1200 DPI 2 12 Spin Motor Module The spin motor module is...

Page 68: ...aster clock source for the fast scan modulation of the laser diode as well as the master clock for the slow scan carriage drive Both clocks operate through Phase Lock Loop PLL systems to average the noise and errors in the encoder disk The encoder also has a once rev or index sensor used to synchronize all of the opto mechanical components This signal generates the Beginning of Line BOL signal 2 1...

Page 69: ...to the upper structure This type of system makes the carriage self contained 2 13 1 1 Friction Wheel Drive Subsystem The friction wheel drive subsystem consists of Spin motor assembly Flywheel The digital and analog encoders Active preload system The precision ball bearings in the carriage housing support the shaft the friction wheel rides along one of the fixed rails guide rail of the linear bear...

Page 70: ...g rides in a fixed V groove rail mounted to the upper structure The friction wheel extends from the opposite side of the carriage housing which rides on a flat rail mounted to a parallel surface on the upper structure 2 13 3 Carriage Home Position Sensor A carriage home position sensor optical establishes a calibration position for the carriage The calibration position establishes a reference poin...

Page 71: ...2 13 4 2 Brushes Three sets of brushes attach to each inner shroud An individual solenoid controls each brush During imaging and certain feed sequences the brushes position either up or down Brush control is determined by the values loaded in the DEC Image Focus Bridge Menu for film paper and plate material NOTE On the Avantra 36 44 the drivers for the brushes are on the SDM board On the 36S 44S t...

Page 72: ...uence moves the media through the take up side After the loading sequence is complete the flappers go up which is called their image position A stepper motor and two sensors control each flapper The sensors tell the system when the flappers are in their load down or image up positions 2 13 5 Vacuum System The Avantra 36 44 has a multi port vacuum system The system contains a 115 volt vacuum pump t...

Page 73: ...h of the media Any width below 26 inches causes one of the valves to open Any width over 26 inches causes both valves to open Figure 2 12 The vacuum valves Two valves Indicators Vacuum pump 2 13 5 3 Vacuum Board The vacuum board controls the vacuum pump and the vacuum valves Refer to Figure 2 12 On off information for the pump and valves comes to the vacuum board via the DEC board 3 2 1 ...

Page 74: ... pump 2 14 Media Transport System Overview The media transport system automatically loads punches advances cuts and rewinds media from multiple supply sources into and out of the drum image area This process entails pulling media out of the supply cassette applying it to the drum firmly affixing the media to the drum and after imaging pushing media into the take up cassette or on line bridge The m...

Page 75: ...ce 2 14 1 Supply Side Mechanics The supply side mechanics consist of the following components Supply drive DC gear motor with encoder for loading unloading media Two DC gear motors for rewinding media into the supply cassettes DC gear motor for A B spindle selection Three drive rollers for loading and unloading media Two spindle sensors Supply jam sensor Supply media present sensor The following s...

Page 76: ...n output If the wheel doesn t move a jam is reported to the control panel 2 14 1 7 Supply Media Present Sensor This sensor which is located in the jam sensor assembly informs the system when media is loaded into the system When the edge of the media passes the sensor during a rewind the sensor stops the supply drive and supply cassette rewind motors 2 14 2 Powered Media Take up Cassette The powere...

Page 77: ...ake up platform Reflective tape which attaches to the bottom of the take up cassette covers a sen sor on the take up platform when the cassette is installed into the system This informs the system when a take up cassette is in position for system operation 2 14 3 Media Punch Clamp Assembly The media punch makes registration holes in the media Refer to Figure 2 15 The punch assembly achieves high a...

Page 78: ...rive assembly applies the appropriate pressure to the take up drive rollers and pushes the media into a take up cassette or into an on line bridge The take up drive assembly consists of two identical drive housings one called the outer nip drive system and the other called the inner nip drive system Both nip systems contain a pair of gear driven rollers each with a center rubber section The roller...

Page 79: ...igure 2 17 The outer nip releases the pressure between the rollers to allow media to pass through on an initial media load The nip release mechanism helps media settle back onto the drum after normal image feeds and clearing jams Two continuous duty DC pull type solenoid mechanisms attached to the outside drive housing perform the take up nip release function Refer to Figure 2 17 Figure 2 17 Outer...

Page 80: ... rollers to disen gage the take up drive but not enough to disengage the drive gear mesh Figure 2 18 The take up drive assembly Outer nip drive system Inner nip drive system Aligned rollers 2 14 5 Media Cutter Assembly An automatic media cutter is provided on the output side of the drum See Figure 2 19 The cutter cuts all required media types including the optional 8 and 12 mil thick film plate ma...

Page 81: ...r mechanism A DC gear motor which attaches to the end of the cutter through linkage drives the cut ter One revolution of the motor output shaft causes the linkage to reciprocate the cutting bar A built in sensor a mechanical micro switch signals when the cutting cycle completes The media cutter assembly also includes the take up media present sensor 2 14 6 Supply Cassette The supply cassette is a ...

Page 82: ... out or rewound Two hub and spindle assemblies one placed at each end of the cassette housing provide support for the media roll and the necessary user width adjustment Machined grooves every inch on the spindles provide a detent position for the hubs to accurately and repeatedly locate the media roll in the cassette One of the hub and spindle assemblies has a gear located at the end which when lo...

Page 83: ... The following sub assemblies make up the humidifier system Humidifier sub assembly Module sub assembly Water supply Electronics module board Float switch water valve solenoid Fan control circuit Interface connections Switched 24 volt driver Fan speed selector The following describes the function of each 2 15 2 Humidifier Sub assembly The sub assembly described below consists of the following A 30...

Page 84: ... water reservoir Three feet of 1 8 inch clear tubing Two quick connect couplings The water supply consists of a frosted vinyl water bag having a pop off spout for filling The water reservoir bag holds approximately 2 3 gallon of water This amount represents a three day supply minimum The reservoir sits in a holder mounted to the outside left of the imagesetter enclo sure A decorative cover painted...

Page 85: ...at switch and water solenoid which are part of the humidifier assembly connect to the electronics module through connector J2 The switch and solenoid represent a closed circuit with the float switch directly controlling the water sole noid valve When the water reservoir is full the normal switch condition is closed A closed switch turns off transistor Q1 which in turn de energizes the water valve ...

Page 86: ...y The humidifier option enables and disables via the operator contol panel OCP configuration screen also see user documentation Pressing the humidifier icon on this screen displays an expanded view of both the option s current and alternate state i e enabled or disable The screen highlights bold type the current state When the humidifier option is not installed the humidifier key shows the humidi ...

Page 87: ...l the humidifier enabled icon replaces humidity low 2 16 2 Water Supply Empty Alert If the humidity level drops below the desired level and persists for more than 15 minutes either following a power on or enabling of the humidifier 5 minutes after the humidity previously came up to the desired level the system does three things A blinking low humidity icon displays An audible alwarm sounds for 15 ...

Page 88: ...oting guide for diagnosing and repairing problems with the vacuum pump system This section provides a detailed description of Power up Boot Diagnostics Power up Boot Diagnostics Overview Power up Boot Sequence Error Reporting Automatic Dial out Feature Boot Error Codes OCP Run Time Application Errors Avantra Diagnostic Program PC Equipment Requirements Software Installation Starting the Program Sa...

Page 89: ...boot diagnostics available on the Avantra system The topics include Diagnostic Overview Power up Boot Sequence Error Reporting Boot Test Descriptions Modem Dial out Features Boot Diagnostic Error Codes 3 2 1 Power up Boot Diagnostics Overview The power up boot diagnostics main functions are Initializing the system at reset Performing confidence checks on the electronics report errors Supporting th...

Page 90: ...ed and or modem dial out routine executes If the boot is successful the DIAG micro controller gives up its mastership role to the DEC K 4 3 2 2 Power up Boot Sequence The power up boot sequence starts with a reset to the DIAG micro controller At reset the DIAG micro controller is programmed as the master of the SPI bus and is initialized as follows Serial Communication 9600 baud 8 data bits 1 stop...

Page 91: ...PI communication tests exe cute between the DIAG and DSP The DSP firmware revision appears on the OCP The DSP core tests are executed The OCP updates the progress bar as the tests pass Next the DEC K4 micro controller is taken out of reset SPI communication tests execute between the DIAG and DEC K4 The DEC firmware revision appears on the OCP The DEC core tests execute The OCP updates the progress...

Page 92: ...s bar updates If a test fails during the boot sequence error information appears on the control panel The upper right hand corner displays a blinking icon of a service engineer Below the icon a three 3 digit error number appears At this point either address the error or ignore it and continue the boot sequence to operation of the system possibly in a degraded fashion Proceed by pressing the icon w...

Page 93: ... bytes are a sequence of zeros used to retrieve the previous three bytes written As the data is read back it gets shifted left by 5 3 2 3 6 Ongate Register Test The ongate register test writes a 6 byte sequence where the first three bytes repre sent the test data and the last three bytes are a sequence of zeros used to retrieve the previous three bytes written As the data is read back it gets shif...

Page 94: ...a pattern is written into the SRAM Each write in auto increment mode increments the address pointer After the SRAM has been written the offgate register reloads with the same starting address The contents of the SRAM are read back and compared against the expected data pattern Dispari ties are reported as an error 3 2 3 12 Correction State Machine The correction state machine provides event synchr...

Page 95: ...t three bytes are a sequence of zeros used to retrieve the previous three bytes written As the data is read back it gets shifted left by 5 DEC Vacuum Register Test writes a 2 byte pattern into the vacuum regis ter The first byte is the real data and the second byte is used to retrieve the feedback DEC to DSP SPI Link Test the Echo command verifies the SPI link to the DSP from the DEC The K 4 sends...

Page 96: ... by reading the sensors If MOTORON is not asserted within 20 milliseconds an error is reported The motor is then de selected The test verifies that the MOTORON bit gets asserted high by reading the sensors If MOTORON bit does not go high within 20 milliseconds an error is reported Video Data Path Test The video data path is tested by inserting a known data pattern at the video input where it would...

Page 97: ... fies that the expected change in the spinner count value was correct This verifies that the spinner encoder was connected It also confirms that the spinner data input port was at least minimally functional before spinner power up is attempted SPI Communications Verify the DSP SPI line connects the output port of the DSP to the DEC and the DIAG processor At boot time the software sets this signal ...

Page 98: ...uring the power up boot sequence the diagnostic firmware attempts to call out to a remote field service site in the event of an error The number dialed is pre stored in the modem s configuration profile At the beginning of the boot sequence the firmware sends an attention command AT to the modem and waits for a response If the modem responds with an OK the dial out feature enables If there is no r...

Page 99: ... then hangs up the connection and tries again If a response is received it is compared first against a CONNECT message If a match occurs the firm ware proceeds to the login procedure If the response is BUSY or NO CARRIER the firmware hangs up waits four minutes and tries dialing out again This continues until a CONNECT message is received 3 Login Procedure Once a connection has been established th...

Page 100: ...46 Spinner DAC failed 147 Take up servo DAC failed 148 Supply servo DAC failed 149 Spinner did not lock 150 Offgate register failed 151 Ongate register failed 152 Vacuum register failed 153 Diag to OCP handshake failed 154 Diag to DSP handshake failed 155 Diag to DEC K 4 handshake failed 156 DEC K 4 offgate register failed 157 DEC K 4 ongate register failed 158 DEC K 4 vacuum register failed 159 D...

Page 101: ...failed 183 Take up nips motor on failed 184 Take up nips motor off failed 185 Take up cutter motor on failed 186 Take up cutter motor off failed 187 Take up cassette core motor on failed 188 Take up cassette core motor off failed 191 Image Buffer Error Bit set 192 Image Buffer Buffer not ready 193 Image Buffer Packet Count not equal to 2 194 Image Buffer Error Bit remains set 195 FlapperA Motor ON...

Page 102: ... Door Open 14 Missed Breakpoint 15 No RIP Cable 17 Spinner Over Speed 22 Spot Changer Jam 23 Check Sum Error 27 Processor Off Line Warning 28 EEPROM Error 31 Supply Punch Jam 33 No Media Loaded 34 Take Up Cassette Full 36 Supply Cassette Select Jam 37 Take Up Cassette Core Jam 38 Focus Jam 39 Polarizer Jam 40 Diagnostic Error 41 Bridge Not in Position 42 Right Door Open 43 Unknown SPI Command 44 C...

Page 103: ...ed 66 Media Runaway 67 Media Blocking T U Sensor 68 Jam in Buffer Before Buffer Entry 69 Jam in Buffer Before Purchase Sensor 70 Jam in Buffer Before Exiting to Processor 71 Jam Moving Buffer Carriage 72 Jam Moving Bridge Shuttle 73 Bridge Up Cannot Move Shuttle 74 Bridge Foot Missing 75 Bridge Communication Overflow 76 Bridge Jam Before Exit Sensor 77 OLP Front Sensor Not Reached 78 OLP Rear Sens...

Page 104: ...he Agfa Print Engine Interface Specification APIS but do not follow that specification fully The Avantra Diagnostic Program can be used locally with a direct connection or remotely via a modem 3 3 1 Equipment Requirements Several items are required prior to the use of the Avantra Diagnostic software The first item is a portable computer PC We recommend the Dolch 386 since the Avantra diagnostic so...

Page 105: ...software includes the Avantra diagnostic executable file and a set of predefined command files Use the following procedure to install the software 1 Turn the PC on and wait for the DOS prompt 2 Insert the Avantra Diagnostic software floppy disk into the drive 3 Type in the following C a install c avantra RETURN Install bat is a self extracting compressed file that creates all the required director...

Page 106: ... I O panel 3 The imagesetter should be powered up at this point and in an idle state Turn on the PC change to the Avantra directory and start the program Type C avantra avdiag RETURN Upon execution AVDIAG sends out an enter service MXES111111 com mand to the imagesetter s remote diagnostic port This puts the imagesetter in a state to accept and perform commands sent to the port NOTE This state ren...

Page 107: ...loop on a test in certain modes The test modes are Single Pass runs test only once displaying pass fail error code Continuous runs tests the number of cycles entered ignoring errors Halt Error runs tests the number of cycles entered stopping if an error occurs Test Function DEC Tests DEC K4 Module Test DAC Ramps Ramps cycles for O Scope Monitoring Carriage Tests Carriage Movement Tests Media Tests...

Page 108: ...ath Test for 1200dpi VIDTEST bit at beam on Vid Path 18 Test Post PWM Video Path Test for 1800dpi VIDTEST bit at beam on Vid Path 24 Test Post PWM Video Path Test for 2400dpi VIDTEST bit at beam on Vid Path 36 Test Post PWM Video Path Test for 3600dpi VIDTEST bit at beam on Supply Punch Test Supply Punch Motor on off bit tests at 0 current Spindle B Test Spindle B Motor on off bit tests at 0 curre...

Page 109: ...e tests on the PC will post an error All Ramps On All Ramps Off Density DAC Mag DAC Linearity DAC PWM DAC DSP DAC CARRIAGE TESTS Test Function Carriage Slew Carriage over max travel distance Focuser Move Focuser over max travel distance Spot Changer Move Spot Changer to each resolution setting Polarizer Move Polarizer over max travel distance ...

Page 110: ...damaged OCP TESTS Test Function Cutter Executes a Media take up Punch Take up Punch Execute a Head Clamp Punch Home sequence Supply Punch Execute a Tail Clamp Punch Home sequence Nip Solenoid Open Close Nips Spd Selector Moves from one spindle to the other Spd Motor A Turns Spindle Motor A On Off Spd Motor B Turns Spindle Motor B On Off Supp Feed Motor Turns Feed Motor On Off Tkup Align Motor Turn...

Page 111: ... DSP FlashRom Checksum Display DSP Code FlashRom Checksum Diag DSP Hndshk Verify Diag DSP Communications in Master Mode Diag K4 1 Hndshk Verify Diag K4 1 Communications in Master Mode DAC Zeroing Test Zero the DACs CarrDac Low Range Test Carriage DAC at Low Range Supp CurrDAC Test Test Supply Current DAC Tkup CurrDac Test Test Takeup Current DAC Spinner DAC Test Test Spinner DAC Takeup DAC Test Te...

Page 112: ...load old default values or zero out some machine parameters This causes system problems if the backed up machine parameters are not downloaded to the imagesetter after running these tests Some of these command files have been eliminated from newer releases of AVDIAG software Command Function SETMPS52 CMD Sets Media Parameters prior to FSB 10 SHIP CMD Used by Manufacturing prior to system being shi...

Page 113: ...mmands not yet supported by AVDIAG commands not yet defined in the imagesetter firmware and error messages Commands are case sensitive For example the following command opens nips MXDS018E Batch Commands Allows the user to send SPI commands to the imagesetter The CMD files are made up of SPI commands Edit these files for SPI commands These commands are case sensitive Examples are ATI Input Output ...

Page 114: ...kness Allows for different thickness media to be used Media Width Allows for media widths of 01 increments Bridge Up Sensor Enable disable Bridge up Sensor AV44 30K Spinner future option Multiple Spot Flag SGM with four aperture flags all AV44 APIS Buffer Avantra with APIS Buffer option AV44 Extra Supply Feed An additional 4 inch feed during new media loads Carr Home Ea Image Home carriage after e...

Page 115: ...On OFF Turn the beam on off Resolution Beam On Set the Resolution Gate Start Beam On Start of where the Beam turns On BOL Position Beam On Set the beginning of scan line position Gate Length Beam On Set the length of the beam 25 Inches Focus HOME Move the focuser to the HOME position Focus IN Move the focuser in by the amount set by Steps to move Focus OUT Move the focuser out by the amount set by...

Page 116: ...new encoder constants to DEC EEPROM The user should reboot the imagesetter after running this test To view new values load down DEC Machine Parameter and select DEC Plate DSP DEC Machine Parameters NOTE To view the following parameters you must first load down the DEC machine parameters See Section 3 3 4 1 Image Focus Selecting Image Focus displays a dialog box that shows the current image and foc...

Page 117: ...e Focus Position Buffer Med Spd 11421 PWM 1200 Focus Steps Mil 22 Bridge On Delay 1 PWM 1800 Focus Motor Rate 15300 Ubr FastSp Thin 4500 PWM 2400 Polarizer Rate 1600 Ubr SlowSp Thin 6500 PWM 3600 Spot Motor Rate 4500 Lbr SlowSp Thin 62 Magnification Beam Comp Rate 1600 Lbr SlCurr Thin 70 Linearity Beam Comp Offse BrOffElyTimThin 90 SlowScan MAG Ubr FastSp Thick 5500 SlowScan PHASE 0 Ubr SlowSp Thi...

Page 118: ...lt is 11421 Increasing this value decreases the speed UpBrdg Fast Spd The fast speed of the upper bridge motor which properly maintains the slack loop Default is 4500 thin and 5500 thick Increasing the value decreases the speed UpBrdg Slow Spd The slow speed of the upper bridge motor which properly maintains the slack loop Default is 6500 thin and 5500 thick Increasing this value decreases the spe...

Page 119: ... 3000 W8 3000 Parameter Parameter Parameter Parameter S Feed Speed TU Align Cur N 128 TU Start Dly 0 PP PushDist 33 S Hold Speed 12 TU Wind Cur N 75 TU Dly Dist 100 PP PushCurr 24 S Hold Curr 25 TU Align Cur W 128 TU Beg IRge 112 PP PushSpd 8 S Rew Curr 255 TU Wind Cur W 75 TU End IRge 204 PP HPul Len 5 S A B Offset TU Align Cur Pl 128 ImgFd Cst Dly 10 PP HPul Spd 1 S TU Delay 0 TU Wind Cur Pl 75 ...

Page 120: ...supply motor during feed Supply Motor Comp Current 0 255 Current of supply motor during compression Supply Motor Comp Speed 0 255 Speed of supply motor when going into compression Supply Feed Speed 0 255 Speed of supply motor during feed Supply Hold Speed 0 255 Supply hold speed for punchless systems Supply Hold Current 0 255 Supply Hold Current for punchless systems Supply Rewind Current 0 255 Cu...

Page 121: ...hes T U Cass Beg Illegal Range 0 255 Beginning of the range which the media is not supposed to stop 6 inches T U Cass End Illegal Range 0 255 Defines the zone in which the leading edge of the media is not supposed to stop 12 inches Img Feed Coast Dly The media is allowed to coast to a stop to allow time to check the optical sensors i e the media present sen sors Default is 10 ten Takeup Ramp Start...

Page 122: ...te 6 8 wide Plate 9 12 narr Plate 9 12 wide DSP DSP Offset DSP Data S Feed Curr 24 0x50 24 0x53 24 0x56 24 0x59 24 0x5C 24 0x5F 32 0xB2 32 0xB5 0 0x3C 0x T Comp Curr 24 0x51 24 0x54 24 0x57 24 0x5A 24 0x5D 24 0x60 28 0xB3 28 0xB6 1 0x3D 0x T Comp Spd 6 0x52 6 0x55 6 0x58 6 0x5B 6 0x5E 6 0x61 6 0xB4 6 0xB7 2 0x3E 0x Nip Cycle 61 0x44 41 0x46 41 0x48 3 0x3F 0x Nip Incr 60 0x45 40 0x47 40 0x49 4 0x4D...

Page 123: ...an be written to the imagesetter by typing in a new value in the appropriate parameter Listed below is a typical customer s User Parameters menu Parameter No Value Resolution 02 1200 Page Size 03 30000 Feed Default 06 15 Unit of Meas 07 2 Output Device 13 0 Supp Cass No 15 1 Video Mode 17 0 Media Usage 24 5 Fast Scan Coord 25 0 Slow Scan Coord 26 0 XY Coord Opt 27 0 Interpage Spac 45 1 Feed Cut Le...

Page 124: ...5 Density 3600 DPI 05 115 190 200 175 175 Media Left 08 1902 2500 1809 1895 0 Media Type 14 1 1 1 1 1 Punch Enable 22 2 0 0 0 0 Media Width 27 64800 57600 57600 57600 57600 Media Thickness 47 4 4 4 4 4 Image Position 66 540 540 540 540 540 Operational Statistics Selecting OP Stats displays a dialog box that shows the operational statistics stored in the imagesetter in OCP EEPROM The software retri...

Page 125: ...s a dialog box that shows a scrolling list of errors logged in the imagesetter The error log contains the last 64 errors both boot and applica tion encountered by the system If the system supports real time clock then only the last 30 errors will be displayed The error codes are in DEC EEPROM The soft ware retrieves the error log from EEPROM upon entering this menu selection Clear the error log by...

Page 126: ... 0 Humidity 1 0 Supply Punch Punch 0 0 TSCREWOFF 0 1 Flapper B Load 1 1 Supply Punch Clamp 0 1 SLACKLOOP 0 2 Supply Jam Wheel 1 2 Supply Cass Selected B 0 2 BRPURCH 0 3 Flapper B Image ON 1 3 Door Interlock Left ON 0 3 SHTTLELT 0 4 Door Interlock Right ON 1 5 Supply Media Present ON 0 4 SHTTLEHVY 0 5 Supply Cass Selected A ON 3 0 Takeup Punch Punch 1 0 BRDGDOWN 2 0 Takeup Jam Wheel ON 3 1 Takeup P...

Page 127: ... load down sensor RowCol 23 Take up cassette core sensor RowCol 24 Take up Cassette present sensor 18 RowCol 25 Right Flapper image up sensor RowCol 30 Take up punch punch switch RowCol 31 Take up punch clamp switch RowCol 32 Take up cutter home RowCol 33 Carriage home sensor RowCol 34 Spare RowCol 35 Take up media present sensor RowCol 40 Spot size changer aperture sensor RowCol 41 Polarizer home...

Page 128: ...d 5 This test should be performed after replacing either servo motor or supply take up SDM boards Imagesetter Primitives This menu item executes imagesetter primitives usually executed by commands sent between micro controllers via the SPI communication link Menu Item Function Spinner ON OFF Turn the spinner on off Carriage Home Position Set the carriage home position HOME Carriage Move the carria...

Page 129: ...ead Punch CLAMP MXDS01AA Head Punch PUNCH MXDS01AB Tail Punch HOME MXDS01A6 Tail Punch CLAMP MXDS01A7 Tail Punch PUNCH MXDS01A8 Takeup Cassette Forward MXDS019D Takeup Cassette Align MXDS019C Takeup Cassette OFF MXDS019E Supply Cassette B Rewind MXDS01B0 Supply Cassette A Rewind MXDS01B1 Supply Cassette OFF MXDS01B2 Go to Spindle B MXDS01A4 Go to Spindle A MXDS01A5 Spinner ON Spinner OFF Vacuum ON...

Page 130: ... Drive Fast Front drive system running in fast mode Rear Drive Fast Buffer drive system running in fast mode Rear Drive Slow Buffer drive system running in slow mode Short Feed Shuttle ON CW Moves bridge to light mode Shuttle ON CCW Moves bridge to heavy mode Shuttle OFF Turns shuttle motor off Brake ON CW Applies brake to buffer rollers Brake ON CCW Applies brake to buffer rollers Brake OFF Remov...

Page 131: ...age setter XMG02 which signals that the boot completed Issue a New Engine Restart command after a reset to prepare the imagesetter for diagnostic commands This is the preferred reset since it is non destructive to EEPROM values that may have changed Hard Reset This menu selection issues a hard Reset command A to the imagesetter The imag esetter immediately resets will not save OCP EEPROM values an...

Page 132: ...s This menu selection brings up a dialog box with a list of modem functions per formed by the AVDIAG Dial out This item initiates a dial out sequence Hang Up This item causes the modem to drop the carrier and disconnect It uses the hang up string defined in the modem command strings Modem Command Strings This item modifies the default modem strings such as the dial out modem initialization and han...

Page 133: ...r NVRAM phone number to dial out ATDS1 Monitor Mode This menu selection places the system in a special mode where direct entry of modem commands can be executed It is also used to monitor boot progress after the imagesetter has been reset Execute PC Imager NOTE For this function to work properly first launch the PC Imager program to the PC and execute AVDIAG from that program s utility menu see th...

Page 134: ...ter password The user is asked for the original password before allowing a new password to be entered Toggle Comm Display Selecting this menu item enables or disables the monitoring of the APIS commands to and from the AVDIAG program This mode is usually used in program debug ging mode Feed Error Disable This menu selection allows the user to disable both film feeding and error report ing Set Real...

Page 135: ...enu contains several modes for exiting the AVDIAG program Exit Modes The following lists and explains the methods of exiting Exit Exits the program immediately without any imagesetter reset Soft Reset Exit Causes the AVDIAG to first issue a soft reset as described previously await a ready condition from the imagesetter and then exit the program Hard Reset Exit Causes the AVDIAG to first issue a ha...

Page 136: ...n and allow the boot cycle to complete 3 Launch the AVDIAG Program from your PC 4 Under the ALIGN menu select DEC Machine parameters and press ENTER A message appears querying whether the machine parameters should be loaded Press Y The parameters load from the system into the PC s memory A dialog box appears with a list of actions that can be performed 5 Select Save to File and press ENTER Another...

Page 137: ...hine Parameters into memory 5 Select N in the dialog box and press ENTER 6 Select Restore to Engine and press ENTER 7 A dialog box appears with all the saved DEC files Select the file with the same serial number and extension saved in Step 7 in the save procedures above and press ENTER The Machine parameters will now load to the imagesetter When com pleted the following dialog boxes appear Dec EEP...

Page 138: ... from your PC 4 Select FLASHROM and then Save CORR table 5 A dialog box appears for Pathname Filename Press ENTER 6 The Pathname Filename appears using the system serial number and extension Press ENTER The DEC correction tables will be saved to the PC NOTE If you have previously saved the DEC DSP software or have a newer revision store in AVDIAG then you do not have to save it again 7 Select FLAS...

Page 139: ...rases the DEC FLASHROM and loads the two files selected DSP code Correction Table 6 When the load completes press any key and wait for the Avantra to reset 3 3 4 3 Save Restore Operator s Control Panel OCP User Parameters Use this procedure to save OCP user parameters to the PC or restore OCP user parameters from a PC back to the system The parameters being saved restored reside in the OCP micro c...

Page 140: ...OCP user and cassette parameters are saved to a file To Restore 1 Connect your PC to the diagnostic serial port of the system 2 Turn the system on and allow the boot cycle to complete 3 Launch the AVDIAG Program from your PC 4 Under the Align menu select OCP User Parameters and press ENTER A dialog box appears Loading OCP EEPROM User Parameters and OCP Cassette Parameters into memory 5 Select N an...

Page 141: ...unch the AVDIAG Program from your PC 4 Under the FLASHROM menu select Prog OCP and press ENTER 5 Select RAW and then the latest OCP revision software file 6 Press ENTER A dialog box appears The following file has been selected to download to the OCP FlashRom Select Y in the dialog box The control panel should go blank then flash during the the control panel FLASHROM erasure In the top left corner ...

Page 142: ... system 2 Turn the system on and allow the boot cycle to complete 3 Launch the AVDIAG Program from your PC 4 Under the FLASHROM menu select Prog DEC K1 and press ENTER 5 Select RAW and then the latest DEC K1 firmware revision 6 Press ENTER A dialog box appears The following file has been selected to download to the K1 FlashRom Filename Select Y in the dialog box The system erases the DEC K1 FLASHR...

Page 143: ...hRom Filename Select Y in the dialog box The system erases the Bridge FLASHROM and loads the new Bridge soft ware When completed a dialog box appears Press any key to continue 7 Press a key and wait for the system to reset 3 3 4 7 Creating Correction Tables The Avantra has twelve Correction Tables Ten of the twelve tables are identical for all Avantras Avantra 20 25 Avantra 36 44 Avantra 36S 44S a...

Page 144: ...riate parameters set so that we can measure it and send you back a new diskette with just the new L files This is usually done when a spin motor is replaced It is very important that when a carriage assembly is replaced that the new Correc tion Table plus the DQ and L files are replaced on the original system diskette The same is true if just new L files are sent to correct Linearity problems The ...

Page 145: ...of your PC This message displays on the PC Avantra Corrutil Version 3 06 NOTE The Version number may change depending on the version of the Correction Utility program loaded in your PC 3 Enter the machine serial number leading zeros not needed 4 Enter the engine type from the table below 1 Avantra 25 20K for AV20 25 with DEC B boards 2 Avantra 36 44 13 5K for standard AV36 44 systems 3 Avantra 25r...

Page 146: ...a dxxxxxh 007 Processing input file a dqxxxxxl 007 Largest fit error is x xxxxxx Created output file a dxxxxxl 007 Initializing from INIT c avantra download cor_xxxx hex NOTE Note The cor_xxxx hex is the Default Correction Table for the system you are creating the new correction table for INIT_HEX version is xx xx Version number of correction table Processing table a dxxxxxh 001 Processing table a...

Page 147: ...vantra download directory must be merged with the correct DSP software using the Prog DSP CORR in Avdiag FlashRom menu The new Correction Table plus the DQ L files should be copied to your origi nal system floppy diskette When you send in a scale file to be measured for linearity correction you will only receive the L files You must copy the DQ files from the original system diskette to the disket...

Page 148: ...te connection is other than that recommended unpredictable results may occur Remote Site Equipment Modem and modem part numbers are subject to change Refer to OMNI Bulletin Board for latest revision of AVDIAG Imagesetter Equipment Modem and modem part numbers and power cables are subject to change Equipment Part Number Dolch PC or equivalent 78461 501 Modem Zoom 80007 001 Avantra Diagnostic Disket...

Page 149: ...telephone numbers and 2 configurations of modem settings Weight 7 4 ozs 210 grams Dimensions 4 9 x 2 7 x 1 12 4cm x 7cm x 2 5cm Interface RS 232C Telephone Interface RJ11 Receive Sensitivity 43 dbm Transmit Level 12 dbm Input Power 9VDC 300 ma Environment 32 to 133 operating 40 to 140 non operating The dimensions are critical only if installation of the modem inside the Avantra is desired The mode...

Page 150: ...led information on the modem configura tion settings Table 3 3 Table 3 4 To ensure proper operation of the modem certain registers and non volatile config uration parameters must be pre set prior to installation A PC or terminal is required to set these values Table 3 2 lists the commands registers that must be pre set COMMAND DESCRIPTION E0 Echo Off V1Word Responses D0 Modem Ignores DTR Ready Sig...

Page 151: ...ing clip on the modem bracket and remove the clip 3 Slide the modem into the bracket with the connectors facing out Re install the mounting clip 4 Locate the power and diagnostic port connectors on the DEC PCB bottom of electron ics enclosure 5 Plug the DC power cable into the DEC and route the cables along the bottom of the door up to the modem 6 Plug the power connector into the modem 7 Connect ...

Page 152: ...are Connection After the modem has been configured perform the following procedures 1 Connect the 9 pin end of the modem serial cable to the appropriate serial port of the PC 2 Plug the DIN connector into the modem NOTE Depending on the PC used a 9 to 25 pin adapter cable may be neces sary to connect the modem cable to the PC s serial port COMMAND DESCRIPTION E0 Echo Off V1 Word Responses D0 Modem...

Page 153: ...ake a remote connec tion to the Avantra Make sure that the system is turned on that all jobs have been cleared from the drum and that other users have been informed not to send jobs to the Avantra 4 Turn on the PC and start the Avantra Diagnostic Program Type C avantra avdiag 5 If the AVDIAG has been set up for remote communication on boot up a dialog box with a list of phone numbers to dial appea...

Page 154: ...t MXRE command to the Avantra the program issues a hang up command to the modem Make sure that the carrier detect LED goes out signaling that the connection has been terminated 4 Call the customer site on the voice line to inform them that the Avantra is back on line 3 5 Vacuum System Troubleshooting Guide The following is an aid to troubleshooting the Avantra 36 44 vacuum system Refer to the trou...

Page 155: ...ove the electronics box see Section 4 8 Vacuum in Chapter 4 Imagesetter Component Removal Replacement Procedure Locate the vacuum pump wires brown and blue inside and discon nect them g Install a new fuse plug the system in and turn it on Continue to Step 5 5 Using AVDIAG choose a Align b Primitives c Vacuum ON d Check the AC line going into the pump assembly Using a DVM mea sure the voltage acros...

Page 156: ...AC Going into SSR Replace Vacuum Pump Yes Yes Vacuum System Fixed Vacuum System Fixed Is Voltage OK No Check Input Side of SSR Is Voltage OK No Check DEC Signal Replace Vac Mod Replace Solid State Relay Yes Yes Check Output of Transformer Is Voltage OK No Yes Check Wiring Replace Volt Sensing Relay Check Input of Transformer Is Voltage OK No Yes Replace Transformer Check Wiring to the Input of Tra...

Page 157: ...V OUT 115V MID 0V MID 115V OUT 0V OUT 100V 0V MID 100V 115V MID ESS FUSE 3A TRANSFORMER From DEC Bd Digital signal to turn Punp ON 24VDC Turns Inner Vacuum Solenoid ON 24VDC Turns Outer Vacuum Solenoid ON 24VDC Turns AC ON to Vacuum Pump 24VDC From Vacuum Module to turn AC ON to Vacuum Pump VACUUM MODULE PCB ORANGE CONNECTOR OUTPUT SIDE GRAY CONNECTOR INPUT SIDE Green LED 110v OFF 220v ON ...

Page 158: ...g a DVM to measure the AC voltage across the following two points 0V Outside Gray Conn At 110 V 110 V 115V Outside Gray Conn At 220 V 110 V 8 A good voltage reading may indicate a defective or miswired volt sensing relay Replace the volt sensing relay if the wiring is correct 9 If the voltage reading is wrong check the transformer input Using a DVM measure the AC votage across the following two po...

Page 159: ...urn the system on If the operating line voltage is 110V the LED will be off If the line voltage is 220V the LED will be on 6 If the vacuum pump is not operating continues to blow fuses or the LED is not on at 220V refer to Section 3 5 Vacuum System Troubleshooting Guide NOTE Make certain that the sytem s power switch is in the off position prior to plugging the system into the AC power source This...

Page 160: ...r Media Transport Removal Replacement Procedures Take up Light Shield Outer Take up Drive Nip Assembly Inner Take up Drive Nip Assembly Inner Take up Drive Nip Motor Take up Jam Sensor Take up Punch Assembly Cutter Assembly Cutter Motor Take up Media Present Detector Electrical Removal Replacement Procedures Digital Engine Controller DEC PCB Carriage Sensor Driver CSDM PCB Operator Control Panel A...

Page 161: ...ht and Left Spin Motor Module SMM Spot Generation Module SGM Spot Size Sensor Polarizer Sensor Beam Compressor Motor Aperture Wheel Motor Weak Lens Motor Focus Sensor Media Transport Removal Replacement Procedures Supply Drive Servo Motor Supply Cassette A or B Rewind Motors Supply Spindle Select Motor Supply Spindle Select A B Sensors Supply Roller Removal and Installation The Vacuum System Vacuu...

Page 162: ...acement 4 3 4 2 Covers The following describes how to remove the covers and panels 4 2 1 Right Left Side Covers Tools Required None Remove 1 Open the top cover at the front of the imagesetter Figure 4 1 Imagesetter with front top cover open ...

Page 163: ... 2 Loosen the thumb screw located on the inside of the imagesetter Refer to Figure 4 2 Figure 4 2 Thumb screw location Side Cover Thumb screw 3 Swing the left or right side cover out at a right angle from the system Replace 1 Reverse the above procedure 1 2 ...

Page 164: ... 2 2 Top Middle and Bottom Front Panels Tools Required None NOTE The bottom panel is not normally removed Remove 1 Lift the bottom segment of the top cover Refer to Figure 4 3 Figure 4 3 Front of imagesetter Front cover Bottom segment Top segment 1 3 2 ...

Page 165: ...ervice Manual 4 6 Removal and Replacement 2 Lift the top panel up releasing it from the lock slots on either side and pull straight out Refer to Figure 4 4 Figure 4 4 Top panel lock slots Top panel Top lock slots 1 2 ...

Page 166: ...from its lock slots on the sides Refer to Figure 4 5 Figure 4 5 Middle panel lock slots Front panels top and middle Top panel lock slots Middle panel lock slots Bottom panel 4 To remove the bottom panel grasp it at the bottom center lift straight up and pull forward Replace 1 Reverse the above procedures 1 4 2 3 ...

Page 167: ...ws at the bottom of the electronics enclosure Refer to Figure 4 6 3 While holding the electronics enclosure cover with one hand loosen one 1 1 4 hex screw located at the top right side Refer to Figure 4 6 NOTE The screw also secures a cable clamp for the power supply cable going to the control panel Figure 4 6 Electronic enclosure cover screw locations 1 4 hex screw Three 1 4 hex screws 4 Slide th...

Page 168: ... 1 Take up Light Shield 1 Raise the front top cover 2 Remove the top and middle panels See Section 4 2 2 Top Middle and Bottom Front Panels 3 Loosen the three thumb screws at the bottom of the light shield Refer to Figure 4 7 4 Grab the shield by the handles Refer to Figure 4 7 Pull out then up Figure 4 7 Take up light shield Take up light shield Three thumb screws Handles 1 3 2 ...

Page 169: ... Light Shield 5 Remove the foam on either side of the outer take up nip drive 6 Disconnect the nip solenoid connector Refer to Figure 4 8 7 Disconnect the cutter interlock switch cable Refer to Figure 4 8 8 While holding the nip assembly with one hand use a flathead screwdriver to loosen the four 4 screws on the front of the assembly Refer to Figure 4 8 9 Remove the assembly from the system Figure...

Page 170: ...ay Sensors and check the operation of the take up jam sensor The take up jam wheel can be checked by inserting a piece of film down the right side of the take up cassette platform until the sensor wheels move and cause a change in status for the take up jam wheel 6 Load media to check complete feed function 4 3 3 Inner Take up Drive Nip Assembly Tools Required 3 16 allen wrench Remove 1 Unload the...

Page 171: ...ke up drive nip assembly Inner take up drive nip assembly 4 3 16 allen screws securing the drive to the system Motor 2 power cables 1 red 2 brown Encoder cable 7 Disconnect the encoder plug from the motor Refer to Figure 4 9 Make note of the orientation for replacement 8 Cut the two tie wraps on the mesh cable wrap Velcro to the right of the motor Open the cable wrap 9 Open the right side panel Se...

Page 172: ...r to Figure 4 9 12 Pull the assembly out rocking it gently Figure 4 10 Take up SDM board Take up SDM board Sensor cable Replace 1 Reverse the removal instructions to re install the inner take up drive nip assembly 2 The take up drive assembly should be checked for proper operation before the outer covers are installed 3 After installing the outer take up drive assembly and the light shield turn th...

Page 173: ...d function 4 3 4 Inner Take up Drive Nip Motor Tools Required 3 16 allen wrench 1 4 and 5 16 nut driver Remove 1 Unload the media and turn the system off 2 Open the top cover 3 Remove the top and middle front panels See Section 4 2 2 Top Middle and Bottom Front Panels 4 Remove the take up light shield See Section 4 3 1 Take up Light Shield 5 Remove the foam on either side of the outer take up nip ...

Page 174: ...purposes of replacement the power sockets are marked 1 red wire 2 brown wire 10 Disconnect the encoder plug from the motor Refer to Figure 4 9 11 Before removing the motor test the backlash between the drive motor gear and the drive roller gear This same backlash will be required after installing the new drive motor 12 Using a 1 4 nut driver remove the two 2 hex nuts attaching the motor to the bra...

Page 175: ...talling the outer take up drive assembly and light shield turn the system on and launch the AVDIAG program from your PC 8 Select ALIGN and select Engine Primitives to test the take up nip solenoids 9 From the Align menu enter Display Sensors and check the operation of the take up jam sensor The take up jam sensor can be checked by inserting a piece of film down the right side of the take up casset...

Page 176: ...ensor 4 Using a 1 4 nut driver remove the 1 4 hex head screw holding the tie clamp Refer to Figure 4 12 5 Using a 1 4 nut driver remove the two 2 1 4 hex head screws securing the sensor bracket to the take up drive nip assembly Carefully slide the bracket toward the motor to clear the jam sensor wheel Refer to Figure 4 12 6 Using a 1 4 nut driver remove the nut securing the sensor to the bracket R...

Page 177: ...er take up drive and the light shield turn the system on and launch the AVDIAG program from your PC 9 Select ALIGN and then Display Sensors and check the operation of the take up jam sensor The take up jam sensor can be checked by inserting a piece of film down the right side of the take up cassette platform until the sensor wheels move and cause a change in status for the take up jam sensor on yo...

Page 178: ...he chafe direction shield from the system Refer to Figure 4 13 5 Cut the tie wraps on the three 3 vacuum lines and remove the lines from the assembly Refer to Figure 4 13 6 Disconnect the sensor motor connector Refer to Figure 4 13 CAUTION Do not loosen or remove the two 2 3 16 allen screws that secure the punch shoe located to the right of the punch assembly to the drum base Refer to Figure 4 13 ...

Page 179: ...ble Test 6 Select Media Tests and then Take Up Punch The take up punch should move and pass the test 7 Insert a piece of film from the drum surface to the punch assembly Push it in to the punch and check that it moves freely without getting jammed NOTE The punch opening should not be extended beyond the drum surface 4 3 7 Cutter Assembly Tools Required 5 16 nut driver with extension allen wrench 0...

Page 180: ...ION The media entrance and exit guides on the cutter assem bly can be easily bent if they come into contact with a hard surface When working or placing the cutter assembly down always face the mounting plate the plate that was attached to the system in the down position 6 Remove the four 4 3 16 hex screws two 2 on the left and two 2 on the right securing the cutter assembly to the drum Refer to Fi...

Page 181: ...ist the shaft at the end of the motor so that the 5 64 allen screws on the coupler are visible Refer to Figure 4 15 4 Loosen the two 2 allen screws on the coupler and remove the motor shaft Refer to Figure 4 15 5 Remove the four 4 phillips screws securing the cutter motor to the stand offs Refer to Figure 4 15 6 Loosen the two allen screws on the motor cam Remove the motor from the cutter assembly...

Page 182: ... 4 3 7 Cutter Assembly 2 Position the cutter assembly so that the cutter motor is to the right and the mounting plate the plate that attaches the cutter assembly to the drum is facing down Refer to Figure 4 16 Figure 4 16 Take up media present sensor Cutter assembly Take up media present sensor Sensor connector 1 4 hex nut Mounting plates 3 Remove the connector from the media present sensor Refer ...

Page 183: ...move both supply cassettes 2 If the bridge is present put it in light mode Lift the bridge to the up posi tion 3 Push down the cassette A tray to lock Slide the cassette B tray to the out position 4 Remove the two 2 screws which are located under the bottom spindle roller securing the cover to the supply jam and media present sensor assembly 5 Open the left side door and remove the three 3 screws ...

Page 184: ...d Also ensure that a copy of the DEC K1 FLASHROM and DSP FLASHROM software are loaded in the PC Remove 1 Turn the system off and unplug the power cord from the outlet 2 Open the right side cover See Section 4 2 1 Right Left Side Covers 3 Remove the electronics enclosure cover See Section 4 2 3 Electronic Enclosure Cover 4 Disconnect the APIS serial modem modem power cables and the bridge and vacuu...

Page 185: ... behind SDM cable Power supply OCP Vacuum Apis Bridge Modem Modem power 6 Remove the six 6 hex screws from the bottom of the electronics enclo sure securing the DEC plate to the enclosure Refer to Figure 4 18 7 Remove the three 3 hex screws securing the DEC PCB in the enclosure and remove the board Refer to Figure 4 18 5 3 1 6 7 4 2 8 9 ...

Page 186: ... board Six screws located underneath electrical enclosure Replace 1 Install the new DEC board by reversing the above steps 2 Download and restore all DEC machine parameters 3 Download the DEC DSP and correction tables 4 If necessary program the DEC K1 FLASHROM 5 Run the following imager files Continuous mode 1x1 Horizontal Line Stop Start mode 50 85 96 tint 1 2 ...

Page 187: ...n the right side of the system then the light shield on the left side of the system See Section 4 6 1 Light Shields Right and Left This accesses both sides of the carriage assembly 4 On the right side of the system disconnect the flex cable LDM cable SGM sensors cable SGM motors cable digital encoder connector from the CSDM PCB Refer to Figure 4 19 Figure 4 19 Carriage sensor driver module PCB CSD...

Page 188: ...Figure 4 20 Figure 4 20 Carriage sensor driver module PCB CSDM left side CSDM PCB 3 16 hex screws and retaining clip Spin motor cable connector Spin motor encoder cable connector Carriage motor cable connector Analog encoder cable connector 6 Remove the two 2 3 16 hex screws and retaining clip securing the CSDM to the carriage assembly Refer to Figure 4 20 7 Slide the PCB out of the carriage assem...

Page 189: ...ager files Continuous mode 1x1 Horizontal Line Stop Start mode 50 85 96 tint 4 4 3 Operator Control Panel Assembly Tools Required 1 4 nut driver 5 16 nut driver NOTE Prior to removing the OCP assembly ensure that the customer user parameter settings have been saved and a copy of the OCP FLASHROM software is available for downloading Remove 1 Turn the system off and unplug the power cord from the o...

Page 190: ...16 hex screw 4 Remove the hex screw securing the power cord clamp to the electronics enclosure Refer to Figure 4 21 5 Remove the power connector located below the control panel 6 Remove the power connector going to the power supply Refer to Figure 4 21 7 Loosen the 1 4 hex screw securing the OCP assembly to the removable mounting bracket Refer to Figure 4 21 8 Remove the 5 16 hex screw securing th...

Page 191: ...rs have occurred and that the dis play looks correct 4 If the control panel is not up to the latest revision and you have that revi sion stored in your PC then you must reprogram the control panel FLASHROM Refer to Chapter 3 Section 3 3 4 4 Program OCP FLASHROM 5 Restore the previously saved OCP user parameters to the OCP NOTE When the system is turned off it automatically saves all customer param...

Page 192: ...wo 1 4 hex screws Two plastic standoffs Replace 1 Push the SDM s back onto the two 2 stand offs and secure with the two 2 1 4 hex screws 2 Connect all cables removed in previous steps 3 Launch the AVDIAG program from your PC and ensure that all functions work properly for the SDM supply or take up being replaced The following lists the functions that should be tested for each type Supply Take Up S...

Page 193: ... AC outlet 2 Open the right side cover See Section 4 2 1 Right Left Side Covers 3 Remove the electronics enclosure cover See Section 4 2 3 Electronic Enclosure Cover 4 Remove the screw securing the ground wire located behind the intake fan assembly Refer to Figure 4 23 5 Remove the two 2 wires going to the intake fan Note the orientation of the wires for re installation ...

Page 194: ...p on the intake fan securing the cable wires Refer to Figure 4 23 7 Disconnect the connector going to the exhaust fan Refer to Figure 4 23 8 Remove the cable clamp on the rear panel and disconnect the two connec tors going to the bottom drum fan assembly and to the door interlock switches 9 Cut the tie clamps releasing the exhaust fan cable from the cable harness 10 Remove the power connector to t...

Page 195: ... the electronics enclosure while passing the power connector and fan wires through the holes provided in the electron ics enclosure Replace 1 Reverse the removal procedure to re install the power supply 2 Turn the system on and check for proper operation 4 4 6 Main Power Switch Tools Required Pliers 1 4 nut driver Remove 1 Remove the operator control panel See Section 4 4 3 Operator Control Panel ...

Page 196: ...e plate down and out of the OCP 4 Remove the brown and blue wires going to the power switch Refer to Figure 4 24 Note the wiring orientation for re installation 5 Using your fingers squeeze both the top and bottom back of the switch while pushing the switch forward through the control panel bezel Replace 1 Reverse the removal procedure to re install the main power switch 2 Turn the power on and ch...

Page 197: ...e intake fan assembly below the exhaust fan Refer to Figure 4 26 3 Disconnect the wire connector from the exhaust fan Refer to Figure 4 25 Figure 4 25 Exhaust fan location Exhaust fan 4 Cut the tie wraps 5 Remove the four 4 screws securing the exhaust fan from the electronic enclosure and remove the assembly Replace 1 Reverse the removal procedures to re install the exhaust fan 2 Turn the system p...

Page 198: ...wo wires going to the intake fan Note the wire color orientation for re installation 3 Snap out the plastic removable guide and remove the fan filter 4 Remove the four 4 hex screws securing the fan to the mount Figure 4 26 Intake fan location Intake fan Replace 1 Reverse the removal procedure to re install the intake fan assembly 2 Turn the system power on and check intake fan for proper operation...

Page 199: ...fer tool Remove 1 Open the right and left side covers See Section 4 2 1 Right Left Side Cov ers 2 Remove the right and left inner light shields See Section 4 6 1 Light Shields Right and Left 3 Remove the two 2 screws securing the left end carriage stop to the engine frame 4 Assemble the Carriage Transfer Tool Refer to Figure 4 27 Both sides are pinned for proper orientation Figure 4 27 Carriage tr...

Page 200: ...r alignment pin into the hole on the engine upper structure frame Refer to Figure 4 28 Line up the pin on the transfer tool left rail with the hole in the carriage left rail 8 Tighten the transfer tool screw making sure that the alignment lip on the bottom of the transfer tool right rail is up against the bottom of the carriage right rail 9 After the transfer tool is secured make sure that the top...

Page 201: ...g to the carriage board 3 Move the carriage gently to the left side of the drum 4 Remove the two 2 power cable connectors going to the brushes on the inner shrouds 5 Loosen the four 4 screws securing the left inner shroud to the carriage Remove the shroud 6 Loosen the four 4 screws securing the right inner shroud to the carriage Remove the shroud 7 Gently push the carriage assembly onto the carria...

Page 202: ...e of the transfer tool Refer to Figure 4 27 10 Loosen the two 2 retaining bracket screws that hold the bearing retainer bracket in the up position on the transfer tool Refer to Figure 4 27 The bearing retainer bracket moves down to secure the carriage bearings 11 Tighten both retainer screws Refer to Figure 4 27 12 Loosen the two 2 retainer screws that hold the magnet bracket in the up position on...

Page 203: ...rriage assembly Magnetic transfer bracket 13 The magnet retainer bracket moves down to secure the carriage magnets 14 Tighten both retainer screws Refer to Figure 4 27 15 Holding the carriage transfer tool by its handle unscrew the transfer tool from the system and put it on a flat surface with the transfer tool down 1 2 3 ...

Page 204: ...tighten the retainer screws Refer to Figure 4 30 6 Loosen the two 2 retainer screws that hold the bearing bracket in the down position Move the bearing bracket up and tighten the retainer screws 7 Disengage the two locking pins on the side of the transfer tool Refer to Figure 4 27 8 Gently push the carriage assembly from the transfer tool to the system car riage rails Some resistance will be felt ...

Page 205: ...al and Replacement 3 Pull each of the five 5 latch knobs out and twist them so that they rest outside of the lock slot Refer to Figure 4 31 Figure 4 31 Light shield Lightshield Fivelatchknobs Interlockswitch Latch knob lock slot 1 3 2 4 3 3 ...

Page 206: ...hield automatically shuts off the laser and spin motor Replace 1 Reverse the above removal procedure 4 6 2 Spin Motor Module SMM Tools Required 5 32 allen wrench Remove 1 Open the left side cover See Section 4 2 1 Right Left Side Covers 2 Remove the left inner light shield by pulling the five latching knobs See Section 4 6 1 Light Shields Right and Left 3 Remove the spin motor signal and encoder c...

Page 207: ...ws that secure the spin motor mounting bracket to the carriage casting Refer to Figure 4 32 6 Slide the spin motor out of the mounting bracket Refer to Figure 4 32 Replace 1 Orient the alignment key on the spin motor with the slot in the carriage casting 2 Slide the spin motor forward through the mounting bracket 3 Push the spin motor firmly against the front locating pin and tighten the spin moto...

Page 208: ...tains the new polarizer focus home positions and beam com pressor number These values must be entered in the DEC machine parameters after the SGM is installed 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the plastic cover over the SGM assembly 3 Loosen the two 2 allen screws securing the spin motor bracket to the car riage ca...

Page 209: ...r Spot size sensor 11 Aperture wheel motor 12 SGM base Replace 1 Reverse the above removal procedure 4 6 4 Spot Size Sensor Tools Required Small flathead screwdriver cutters Remove 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the sensor shell connector from the Carriage Board 3 Cut all the tie wraps from the spot size sensor ...

Page 210: ...or cable plug from the shell connector removed in Step 2 Replace 1 Reverse the above removal procedure 4 6 5 Polarizer Sensor Tools Required Small flathead screwdriver cutters Remove 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the sensor shell connector from the carriage board 3 Cut the tie wraps from the polarizer sensor co...

Page 211: ...ble plug from the shell connector removed in Step 2 Replace 1 Reverse the removal procedure above 4 6 6 Beam Compressor Motor Tools Required Small flathead screwdriver cutters Remove 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the motor shell connector from the carriage board 3 Cut all the tie wraps from the compressor to th...

Page 212: ...compressor plug from the shell connector removed in Step 3 Replace 1 Reverse the removal procedure above 4 6 7 Aperture Wheel Motor Tools Required Small flathead screwdriver cutters Remove 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the motor shell connector from the carriage board 3 Cut all the tie wraps from the aperture w...

Page 213: ...ture wheel plug from the shell connector removed in Step 3 Replace 1 Reverse the removal procedure above 4 6 8 Weak Lens Motor Tools Required Small flathead screwdriver cutters Remove 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the motor shell connector from the carriage board 3 Cut all the tie wraps from the weak lens motor...

Page 214: ...e plug from the shell connector removed in Step 3 Replace 1 Reverse the removal procedure above 2 Run the FOCUS FIL file from the PC imager to check the focus adjustment 4 6 9 Focus Sensor Tools Required Small flathead screwdriver cutters Remove 1 Remove the carriage assembly from the system See Section 4 5 Carriage Drive Removal Replacement Procedures 2 Remove the sensor shell connector from the ...

Page 215: ...e focus sensor to the bracket Refer to Figure 4 39 Figure 4 39 Focus sensor location Focus sensor 5 Remove the sensor cable plug from the shell connector removed in Step 2 Replace 1 Reverse the removal procedure above 2 Run the FOCUS FIL file from the PC imager to check the focus adjustment 1 ...

Page 216: ...wing describes the media transport removal replacement procedures Refer to Figure 4 40 for media transport motor and sensor locations Figure 4 40 Supply motor and sensor locations Supply cassette A B rewind motors Supply drive motor Spindle A B position sensors Flag bracket Supply spindle select motor 1 2 5 4 3 ...

Page 217: ...ge is installed put the system in light mode and lift the bridge to the up position Shut the system off before the bridge goes back to heavy mode 4 Lift up the light shield cover Figure 4 41 Imagesetter outer and inner covers Top cover Bridge Light shield 5 Remove the supply cassettes 6 Open the right side cover Refer to Section 4 2 1 Right Left Side Covers 7 Remove the outer light shield Refer to...

Page 218: ...ell sur rounding the motors and sensors that secure the ribbon cables coming from the supply SDM and carriage board Refer to Figure 4 42 Figure 4 42 Opening the cable clamps and removing the cables to gain access to the supply motors and sensors Two ribbon cable clamps Ribbon cables Lower cable clamp Bracket 3 1 2 4 ...

Page 219: ...d wire from Pin 1 and the brown wire from Pin 2 on the motor Refer to Figure 4 43 11 Using a 7 64 allen wrench remove the two 2 allen screws securing the bottom of the motor to the motor bracket Refer to Figure 4 43 12 Using a screwdriver remove the two 2 hex screws securing the top of the motor to the sensor flag bracket Refer to Figure 4 43 The two hex screws have standoffs between the motor and...

Page 220: ...t spindle swap and supply motor 4 7 2 Supply Cassette A or B Rewind Motors Tools Required 3 16 and 1 16 allen wrenches Remove 1 Follow the first eight steps in Section 4 7 1 Supply Drive Servo Motor above 2 Remove the red wire from Pin 1 and the black wire from Pin 2 at the end of the supply motor A or B being replaced Refer to Figure 4 44 Figure 4 44 Removing the supply cassette A or B rewind mot...

Page 221: ... A or B motor that was replaced 4 7 3 Supply Spindle Select Motor Tools Required Screwdriver allen wrench phillips screwdriver Remove 1 Follow the first eight steps in Section 4 7 1 Supply Drive Servo Motor above 2 Remove the supply spindle select motor cable from the supply SDM board at connector J 3 Remove the red wire from Pin 1 and the black wire from Pin 2 at the end of the motor 4 Remove the...

Page 222: ...tor coupler screws Imagesetter Light shield SDM board Three light shield hex screws Two mounting screws Supply spindle select motor Figure 4 46 Removing the select motor coupler Coupler housing Coupler Supply spindle select motor Two coupler allen screws on motor shaft side Motor shaft Two housing screws 1 2 4 5 6 3 1 2 3 6 5 4 ...

Page 223: ...ly spindle select motor needs adjustment Perform the test on both and B spindles on both sides of the unit 4 Loosen the two 2 select motor housing screws and twist the motor slightly Tighten the screws 5 Perform the above test until the shim cannot be removed easily 6 Turn the system on and launch the AVDIAG program from your PC 7 Test the motor NOTE The sensor flags may need adjustment 4 7 4 Supp...

Page 224: ... B position sensors Two sensor securing screws Two sensor connectors Replace 1 Reverse the above removal procedure to re install the sensor 2 Turn the system on and launch the AVDIAG program from your PC 3 Select motor A or B to test the sensor NOTE The sensor flags may need adjustment 2 1 ...

Page 225: ...kets are located on the opposite sides of the left and right casting 4 Remove the left and right bottom and top supply cassette guides The top left and right guides are secured by two phillips screws on the inside cast ing and the bottom left and right guides are secured by two allen screws on the inside casting These four pieces are pinned so that they will not require re alignment when they are ...

Page 226: ... roller out because the right bearing sticks to its metal piece on the right side Installing the Rollers Reverse the above directions to re install Install the center roller first followed by the top and bottom roller Note Before installing each roller use a pliers to compress the spring and then put a tie wrap through it so that now the spring is compressed Only use one tie wrap If you use two wr...

Page 227: ...al and Replacement 4 8 The Vacuum System The following describes the vacuum system removal replacement procedures Refer to Figure 4 40 for component locations Figure 4 48 The vacuum system components Vacuum pump Valves Electronics box 3 2 1 ...

Page 228: ... screwdriver remove the two 2 mounting plate screws Refer to Figure 4 49 Remove the plate with the pump on it 4 Using a phillips screwdriver remove the screw holding the grounding wire in place Refer to Figure 4 49 5 Turn the pump on its side and disconnect the connector at the bottom of the plate Refer to Figure 4 49 Figure 4 49 Vacuum pump Tubing fittings Rubber feet Ground wire Mounting plate T...

Page 229: ...nts Rubber mount Four rubber mount screws Replace 1 Reverse the above removal procedure 4 8 2 Vacuum Valves Tools Required Phillips screwdriver Remove 1 Open the right side cover See Section 4 2 1 Right Left Side Covers 2 Using a phillips screwdriver remove the screw one each in the valve tops Refer to Figure 4 51 The valves are located directly to the right of the vacuum pump 1 2 ...

Page 230: ...8 3 Vacuum Board Tools Required 11 32 socket wrench needle nose pliars flathead screwdriver Remove 1 Open the right side cover See Section 4 2 1 Right Left Side Covers 2 Remove the three 3 hex nuts two at the top and one at the bottom hold ing the electronics box in place The electronics box is located to the right of the vacuum pump and valves 3 2 1 ...

Page 231: ... Figure 4 52 Electronics box Electronics box Three hex nuts 3 Remove the three 3 connectors from the vacuum board which is located inside the electronics box on the left hand side Refer to Figure 4 53 Figure 4 53 Vacuum board Vacuum board Sensor relay 1 2 2 1 ...

Page 232: ...le nose pliars squeeze the standoffs in the upper left lower left and lower right corners of the vacuum board 5 Using a flathead screwdriver remove the screw in the upper right corner of the board 6 Pull the board free Replace 1 Reverse the above removal procedure ...

Page 233: ...ocedure Exposure Adjustment Procedure Carriage Home Position Alignment Procedure Focus Alignment System Leveling Procedure Voltage Check Procedure Pulse Width Modulation PWM Adjustment Procedure Carriage Encoder Alignment Procedure Supply Motor Offset Alignment Procedure Take up Cassette Clutch Adjustment Procedure Feed Motor Calibration Test A B Roller and Sensor Adjustment Slack Loop Test Proced...

Page 234: ...ields removed 5 Turn the system on and allow the boot cycle to complete 6 With the PC connected to the diagnostic serial port of the system launch the AVDIAG program 7 Enter the Align menu and select SGM A B Mod Align Enter the following parameter values each followed by Beam ON Resolution 3600 Gate Start 0 Gate Length 44 5 BOL Position Enter an initial value about 32000 NOTE All the above values ...

Page 235: ...s can be expected 11 Select DEC Machine Parameters The following dialog appears Loading DEC EEPROM Machine Parameters 12 Select Y in the dialog box to load the parameters into memory 13 After loading completes select DEC Image Focus cursor down to the BOL Offset parameter field and press ENTER Enter the new BOL offset value determined in Step 8 and press ENTER The value loads into EEPROM Fine Alig...

Page 236: ...al BOL to Punch distance Amount out Amount out 001 BOL Offset units to be added subtracted Original BOL Offset Value 22 000 0 48 0 72 0 24 0 24 001 240 New BOL Offset Value 22 000 240 21 760 11 Enter the new BOL offset value using the AVDIAG Program and rerun the scale file 12 Measure the copy again to insure BOL to punch distance is correct 13 Re adjust as required 5 3 Exposure Adjustment Procedu...

Page 237: ...ometer select the best 50 dot with a Dmax between 3 8 to 4 2 for all four resolutions 12 Enter the new density values in the Cassette Menu on the Avantra control panel 5 4 Carriage Home Position Alignment Procedure Use the Carriage Home Position Alignment Procedure to set the starting position of the carriage assembly on the drum surface in the slow scan direction Position the carriage by entering...

Page 238: ...ual start of image distance Amount out Amount out 00041 Carriage Home value units to be added subtracted Original Carriage Home Value 1500 0 15 0 45 0 30 0 30 00041 731 7 732 New Carriage Home Value 1500 732 2232 NOTE To move the image closer to the edge of the media the car riage home value must be raised 9 Launch the AVDIAG program from your PC 10 Select Align and then DEC Machine Parameters 11 ...

Page 239: ...he Avantra DEC board serial port Connect the Avantra APIS cable to the PC Imager board in your PC 2 Launch the AVDIAG program from your PC 3 Select Align and then DEC Machine Parameters The following dialog appears Loading Dec EEPROM Machine Parameters 4 Select Y in the dialog box The machine parameters now load up to the PC 5 When the load process completes select DEC Image Focus Write down the v...

Page 240: ...10 readings Start with the top vertical pattern Every place there is a black horizontal bar starting at 280 move up until you get to a set of line patterns that are equal The patterns start out dark to light but eventually come equal If the crossover point is between two sets of pattern lines then choose the value between them For example if the crossover happens between 160 and 120 then choose 14...

Page 241: ...Section I Imagesetter Alignment 5 9 Figure 5 1 Vertical and horizontal focus These patterns are only a simulation They are meant to be used as a guide in selecting a correct value ...

Page 242: ... that is low Monitor the level while adjusting the feet CAUTION The system can not be out of level by more than 1 3 or 067 in ft This translates to approximately 26 from one leveler to the other 6 Connect the systems APIS cable to the PC Imager board in your PC and launch the PC Imager program 7 Run a 50 tint PC pseudo continuous test file Before running the test file the start stop parameters mus...

Page 243: ...tages on the DEC at the following locations 5 8 Pulse Width Modulation PWM Adjustment Procedure Run the Pulse Width Modulation Test to check dot gain The Pulse Width Modulation Test was designed to run with AGFA film only For other vendors use the densitometer to select the best 50 dot screen and then select the number to the left Tools Required Densitometer must be able to measure dot gain light ...

Page 244: ...ng on the resolution See Figure 5 2 The starting value 40 and the increment value 20 are the defaults and can be found in the Header These values can be changed in PC Imager under Special Arrays The starting value 40 is at the bottom row of the pattern and increments by 20 until the top row reads 160 10 Mark each row before proceeding Looking at the reference exposure pattern on the right under th...

Page 245: ...m and launch the AVDIAG program from thePC 13 Select Align and then DEC Machine Parameters The following dialog appears Loading Dec Machine Parameters 14 Select Y in the dialog box to load the parameters to memory 15 Select DEC Image Focus and move the cursor down to change the PWM values selected in Steps 9 and 10 for all four resolutions 16 Press ESC 17 Exit AVDIAG with a soft reset Figure 5 2 R...

Page 246: ...c serial port of the system 2 Turn the system on and allow the boot cycle to complete 3 Launch the AVDIAG Program from your PC 4 Select ALIGN and then Carriage Align and press ENTER A message appears warning that the test modifies the DSP machine param eters and queries about continuing 5 Press Y The test starts running and takes approximately 80 seconds to complete When the test completes the res...

Page 247: ...ith a value of 0 in the S Current Offset field 10 Turn Modulation on by first moving the cursor with the arrow keys until the ON field highlights then press ENTER The imagesetter drives the supply feed motor in alternating directions changing rapidly 11 Observe the action of the feed rollers The rollers will be rotating back and forth If either direction is more pow erful than the other you will e...

Page 248: ...f the take up cassette Remove the cassette top cover 2 Remove the two 2 screws securing the bearing retainers on each end of the cassette core Remove the bearing retainers and lift out the cassette core 3 While holding the cassette core in the orientation shown in Figure 5 3 use a force gauge in oz to check the break away force of the clutch a Slowly pull the force gauge in the direction shown in ...

Page 249: ...nd remove both supply cassettes This procedure should be performed whenever a supply or take up servo motor or supply take up SDM board is replaced Prior to performing this procedure you should balance the forward reverse spindle direction of the supply motor by performing the Supply Motor Offset Alignment Procedure To perform the procedure 1 Launch Avdiag from your PC 2 In the Align Menu select F...

Page 250: ...You should not be able to remove the 1 mil shim easily If you can then the supply rollers need to be adjusted first before adjusting the sensors Only the top and middle rollers can be adjusted 2 If the left side disks need adjustment remove one screw from the bow tie plastic piece holding the spindle select rod mechanism Loosen the other screw and move the assembly up or down depending on which sp...

Page 251: ...can get the disks to touch by adjusting the sensors The A B selector sensors should be adjusted so that when the mechanisms leaves one sensor the flag moves directly towards the other sensor It should not move in the opposite direction first and then move towards the other sensor If it does the sensors need adjustment To adjust the sensors 1 First adjust spindle A sensor To adjust loosen the two l...

Page 252: ...adjustment screws Two 5 16 inch screws Two 3 16 inch screws One of two spindle select motor screws Once this adjustment is completed test both spindle A and B disks using the 1 mil shim test to make sure that all six disks touch when that spindle is selected 3 2 1 ...

Page 253: ...on is located on the Secret Screen of the Avantra Control Panel Press the proper key sequence on the Configuration Screen to enter this special screen Refer to Figure 5 6 Figure 5 6 The Secret Screen A Press button 5 2 first A Press button 5 3 first B Press button 1 3 twice or B Press button 1 3 twice C Press button 5 2 again C Press button 5 3 again NOTE If there is an icon in location 5 2 use lo...

Page 254: ...re only four to ten slack loops the bridge speed parameters should be adjusted Per form the following steps a Using AVDIAG download the DEC Machine Parameters Select Image Focus Bridge and locate the Bridge parameters b Adjust the following parameters up or down accordingly by steps of approximately 50 Ubr Fast Sp Thin 4500 nominal Ubr Slow Sp Thin 6500 nominal NOTE Raising the number decreases th...

Page 255: ...ensor with no binding b Adjust the slack loop bracket back and forth to create a larger or smaller slack loop Refer to Figure 2 c Reinstall the front cover loosely with one screw on each side Reboot the system and check the slack loop number as in Step 4 If the slack loop number is still below four perform steps a thru c again until the number reaches at least four NOTE If the slack loop number ne...

Page 256: ...nical Inspection Operational Inspection Cleaning 6 2 General Preventive Maintenance Requirements Before starting the preventive maintenance inspection Discuss the system s performance with the key operator s Determine if any malfunctions occurred since the last service call Verify that all upgrades have been performed Preventive Maintenance should consist of the following procedures Mechanical Ins...

Page 257: ...how to perform these three procedures 6 2 1 2 Carriage Rail Cleaning Procedure Periodic cleaning of the carriage rails keeps contamination out of the roller bearings and keeps rust from building up on the rails Excessive build up of contamination could result in copy artifacts Tools Required Optic Pads P N 78047 002 To Clean 1 Swing open the side door on each end of the system 2 Remove the drum li...

Page 258: ...back and forth or reuse a contaminated section of an optic pad 5 Inspect the mirror Insure that all contamination and streaking has been removed from mirrored surface 6 Repeat Step 4 as necessary until clean 7 Re install the left shroud assembly 6 2 1 4 Punch Remnants The Avantra 36 44 has two sets of punches One on the take up side 5 hole and the other on the supply side 1 hole Each punch has its...

Page 259: ... N 66602 001 every month 3 Replace the exhaust fan filter P N C00305 001 Orange White Black every three months 4 Clean the punch remnants containers every three months 6 2 2 Operational Inspection This inspection insures the quality and proper alignment of the system To Inspect 1 Turn the system on and monitor the boot up sequence 2 Insure that the system successfully completes BCC s and loads the...

Page 260: ... 084 6 2 3 Cleaning The general cleaning procedures described in the following section help avoid contamination of the system due to dust media chaff and other particles that physically interfere with imaging operations Use the following guidelines when performing the cleaning procedure To clean use a tack cloth part number TBD The motion with the tack cloth should be a light blotting in confined ...

Page 261: ...and take up cassettes 4 Using clear packing tape clean the supply rollers rotate the rollers until their entire surface has been cleaned CAUTION When cleaning the supply rollers do NOT substitute any other tape i e masking duct tape etc for clear tape Substitutes may leave a sticky residue on the roller and any residue could cause PERMANENT DAMAGE to the rollers 5 Soft vacuum the following areas S...

Page 262: ... To Clean 1 Open the two 2 side panels 2 Soft vacuum 3 Clean the Side panel interior surfaces and edges Exterior light shields Frame 6 2 3 5 Inner System To Clean 1 Remove the right and left light shields 2 Move the carriage to the center of the drum 3 Soft vacuum the Inside of the light shields Accessible base and engine casting areas 4 Soft vacuum and clean the Drum surface 5 Install the left an...

Page 263: ...dge and install the three top covers 6 2 3 7 Buffer If the Buffer is installed it should be checked and cleaned during every preventive maintenance To Clean 1 Remove the top cover 2 Remove both the left and right side covers 3 Move the buffer carriage to the processor side and clean both rollers using clear masking tape 4 Move the buffer carriage assembly to the bridge side and make sure that the ...

Page 264: ... the following imagesetter specifications Physical Electrical Environmental Functional Physical Specifications Width 73 185 42 cm Height 48 121 92 cm Depth 35 88 90 cm Weight 1700 lbs 771 11 kg Electrical Specifications Volts 115 230 Amp 5 2 5 Rec NEMA 5 20R Power 575 Watts Heat Output 1962 BTU s Environmental Specifications Oper Temp 60 to 80 F 15 to 27 C Absolute Accuracy 70 3 Humidity 45 to 55 ...

Page 265: ... mil Accuracy Duplo 1 25 mils Avantra 36S 44S 1 75 mils Avantra 36 44 Density Range 4 2D to 4 6D Density Variation 2D deviation Dot Gain 2 deviation Line Screens Up to 300 LPI Media Types Red sensitive HeNe Paper Film Plate Paper 250 ft roll 36 26 24 paper sizes only Film 250 ft roll 4 mil Film 148 ft roll 7 mil Plate 100 ft roll 5 8 and 12 mil Media Thickness 4 to 12 mil operator selectable Media...

Page 266: ... Supply SDM ribbon cable AV36 44 36S 44S 201179 508 T U SDM rubbon cable AV36 44 36S 44S Carriage 002637 558 Carriage assembly AV36 44 002893 558 Carriage assembly AV36S 44S 208867 501 Motor encoder A AV36 44 36S 44S 208866 501 Carriage digital encoder P AV36 44 36S 44S 066719 001 Carriage home sensor AV36 44 36S 44S Electronics P00008 502 Carriage drive module AV36S 44S 209710 502 Carriage drive ...

Page 267: ...over gas shock AV36 44 36S 44S 066766 002 Levelling feet AV36 44 36S 44S 057102 001 Door interlock switch AV36 44 36S 44S Media Transport 066486 004 Supply cassette rewind motor AV36 44 36S 44S 066023 002 Supply drive servo motor AV36 44 36S 44S 207548 509 Supply positioning motor AV36 44 36S 44S 066486 002 Take up cassette motor AV36 44 36S 44S C00035 002 Take up cassette motor wheel AV36 44 36S ...

Page 268: ... 108 Focus home sensor AV36 44 36S 44S 066390 108 Beam compressor home sensor AV36 44 36S 44S 002943 501 Spin motor SpeedRing AV36 44 002943 502 Spin motor WestWind AV36 44 002944 501 Spin motor SpeedRing AV36S 44S 002637 556 Spot Generation Module SGM AV36 44 36S 44S Punch Assemblies 207548 508 Take up punch motor AV36 44 36S 44S 207548 504 Supply punch motor AV36 44 36S 44S 066390 107 Supply Tak...

Page 269: ...Volt sensing relay AV36 44 36S 44S 065979 001 Solid state relay AV36 44 36S 44S 067339 001 Vacuum pump transformer AV36 44 36S 44S 209952 501 Vacuum pump assembly AV36 44 36S 44S 209968 501 Vacuum value assembly AV36 44 36S 44S Humidifier 067505 001 Water wick AV36 44 36S 44S 067506 001 Water bag AV36 44 36S 44S P00058 501 Humidifier PC board AV36 44 36S 44S 002858 501 Humidifier box assembly AV36...

Page 270: ...ble 4 25 Application Errors 3 5 Application Firmware OCP 3 4 Assembly Media Cutter 2 31 Assembly Take up Drive 2 29 AT Command 3 11 AT Modem Command 3 3 ATI Input Output 3 26 ATI Port 3 26 Attaching Imagesetter to Buffer Accessories for 1 13 Audio Interface 2 9 2 10 Auto Dial out Feature 3 64 Auto increment Mode 3 7 Automatic Dial out Feature 3 11 login procedure 3 12 modem dial out 3 12 modem han...

Page 271: ...river Module PCB CSDM left side location 4 29 Carriage sensor Driver Module PCB CSDM right side location 4 28 Carriage Test 3 8 Carriage Tests 3 22 Carriage Transfer Tool alignment lip 4 45 alignment pin location 4 40 assembling 4 40 bearing retainer bracket 4 43 carriage bearings 4 43 carriage rails 4 41 carriage stop pin location 4 40 left rail alignment pin location 4 40 locking pin location 4 ...

Page 272: ...replace 4 20 Cutter Home Sensor location 4 22 Cutter Interlock Switch Cable location 4 10 Cutter Morot shaft 4 22 Cutter Motor coupler 4 22 remove and replace 4 22 remove replace 4 22 D DAC 2 10 3 9 DAC Loop Backs 3 9 DAC RAMPS Tests 3 22 DAC Register Test 3 6 DC Motor Solenoid 2 12 DC Rewind Motors 2 26 DC Spindle A B Gear Motor 2 26 DEC 2 4 2 5 2 12 2 14 3 3 3 9 3 10 3 19 3 27 3 29 3 35 4 25 5 2...

Page 273: ...closure Cover remove replace 4 8 screw locations 4 8 Electronics Overview 2 3 Electronics Packaging 2 4 Encoder 2 19 Encoder Signals normalizing 5 14 End Channel 1 8 End Plate locaation 1 8 location 1 7 Engine imagesetter Sensor Display Screen example of 3 39 Engine Configuration 3 27 Engine Controller Digital 2 7 Engine Equipment adapter cable 3 61 modem 3 61 power cable 3 61 Enter Service Mode 1...

Page 274: ... 3 47 Imagesetter Primitives 3 41 Imagesetter Tool Kit 1 5 Imagesetter Top Cover 4 3 Imagesetter Top Panel 4 5 Imagesetter Installation Accessories 1 13 Imagesetter Unlocking 1 13 Imagesetter Unpacking 1 5 Img Feed Coast Dly definition 3 34 inear 2 21 Inner Channel Bolts 1 9 Inner System cleaning 6 7 Inner Take up Drive Nip Assembly location 4 12 4 17 Inner Take up Drive Assembly remove and replac...

Page 275: ...cal Inspection 6 1 Media Cutter Assembly 2 31 Media Menu Item 3 31 Media Parameters 3 49 Media Punch clamp Assembly 2 28 Media Settle Delay definition 3 33 range 3 33 Media Take up Cassette 2 27 Media Tests 3 22 Media Transport 4 9 4 57 Media Transport Removal Replacement Procedures 4 9 4 57 Media Transport Retainer Bracket 1 18 Media Transport Retainer Bracket Preparing the 1 18 Media Transport S...

Page 276: ...l OCP 2 8 3 3 power supply connector location 4 31 ribbon cable location 4 31 Operator Control Panel Assembly remove and replace 4 30 remove replace 4 30 Operator s Control Panel OCP User Parame ters save restore 3 52 Optic Pads 6 3 Optical System spin motor module 2 15 spot generation module 2 15 Optical System Overview 2 15 Opto mechanical Removal Replacement Procedures 4 45 Outer Channel Bolts ...

Page 277: ...dem configuration 3 61 Remote Modem 3 63 Remote Modem Configuration 3 63 Remote Modem Connection Procedures 3 64 Remote Modem Connecting 3 64 Remote Modem Recommended 3 63 Remote Session 3 66 Remote Site Equipment Avantra Diagnostic diskette 3 61 Dolch PC 3 61 modem 3 61 Remote Terminal Error Reportiing 3 5 Removing Light Shields 1 20 Removing Lower Media Transport Retainer Bracket 1 17 Removing P...

Page 278: ... 5 21 SMM 4 47 Soft Reset 3 44 Soft Reset Command 3 44 Soft Vacuum defined 6 5 Software Installation Procedure diagnostics 3 18 Software Diagnostic 3 19 Specifications Avantra Modem 3 62 SPI 3 26 SPI Bus 2 4 3 3 mastership 3 4 SPI commands 3 26 SPI Communication Link 3 41 SPI Communication Tests 3 4 SPI communication tests 3 4 SPI Communications Verify 3 10 Spin Motor 2 19 alignment key 4 48 encod...

Page 279: ...3 34 range 3 34 Supply Roller Removal and Installation 4 66 Supply Side Mechanics 2 26 Supply Spindle Select Motor location 4 57 Supply Take up Cassette Area cleaning 6 6 Switch Main Power 4 36 System installing moving leveling procedures 5 10 System Architecture 2 4 System Leveling Procedure 5 10 System Overview 2 3 System Parameters Save and Restore 3 49 Systems Operational Lifetime Statistic Me...

Page 280: ...23 Tie Down Bracket 1 16 Toggle Comm Display 3 47 Tool Kit 1 5 Tools diagnostics 3 1 Top Cover location 4 58 Top Cover Imagesetter 4 3 Top Panel location 4 6 lock slots location 4 6 Training Customer Application 1 24 Transfer Tool carriage installation 4 45 carriage removal 4 42 Transfer Tool Installation 4 40 Transport Retainer Bracket 1 17 Troubleshooting Sensor Problems 3 39 U Unlocking the Car...

Page 281: ... fan filter 6 4 lower interior area 6 7 soft defined 6 5 supply cassettes 6 4 supply take up cassette area 6 6 take up module area 6 6 Velocity Error Signal 5 14 Verification Phase Lock Loop 3 10 Video Data Path Test 3 9 Voltage Check Procedure 5 11 W Wall Condition 3 8 Weak Lens 2 18 5 7 Weak Lens Motor location 2 16 4 50 4 55 remove and replace 4 54 Work Space 1 2 ...

Page 282: ...Section II Bridge ...

Page 283: ... takes you through the necessary procedures Removing the Imagesetter Top Cover Attaching the Capture Bar to the Bridge Raising and Lowering the Bridge into the Imagesetter Attaching the Bridge to the Imagesetter Attaching the Bridge Foot Attaching the Gas Shocks Adjusting the Detent Plate Aligning the Solid Stops Setting up the DEC to Bridge Buffer Interface Attaching the Ground Wires ...

Page 284: ...gesetter the top cover must be removed Steps Tools required Screwdriver 1 At the rear of the imagesetter remove the allen screws attaching the top back panel Refer to Figure 1 1 2 Raise the top cover Figure 1 1 Rear of the imagesetter Top cover Hinge stop Hinge stop bolt Gas shock retaining bolt Top back panel allen screws 2 1 1 1 2 ...

Page 285: ...inge Gas shock retaining bolt Gas shock Top and bottom shoulder screws remove Side shoulder screw remove 4 Drop the top cover down 5 Standing at the rear of the imagesetter loosen the two 2 hex head screws from the hinge assemblies left and right Refer to Figure 1 3 6 Slide the bracket out Refer to Figure 1 3 Figure 1 3 The top cover hinge assembly Top cover hinge assembly Two hex screws loosen 4 ...

Page 286: ...ver Refer to Figure 1 3 Figure 1 4 Top cover bottom segment Front panel Bottom segment Top segment CAUTION Use at least two people when performing the next step i e lifting the top cover 8 With a strong person or persons on each end lift the top cover straight up from the imagesetter 1 3 2 ...

Page 287: ...ll need the bridge accessories kit which came with the imagesetter Open the accessories box and check its contents Steps 1 Place the bridge top up on a raised surface near the on line processor crane NOTE Do not attach the crane s cable hook onto the capture bar eyelet until the capture bar is secured to the bridge 2 Remove the light shields in the top part of the bridge 3 Remove the two 2 screws ...

Page 288: ...two 2 9 16 bolts and washers provided secure the bracket to the side of the bridge Refer to Figure 1 6 6 Insert the roll pin side of the bar into the bracket 7 Insert the cap side of the bar into the right bracket 8 Using the bridge screws attach the right bracket to the bridge Refer to Figure 1 6 9 Using the remaining 9 16 bolt and washer provided secure the right bracket to the side of the bridg...

Page 289: ...p the cable to the eyelet and raise the bridge slowly 3 When the bridge height exceeds the height of the imagesetter swing the boom around Suspend the bridge over the imagesetter 4 Before lowering the bridge grease the V groove and flat surface on the detent plates left and right located within the imagesetter Refer to Figure 1 7 Use the grease and applicator provided Figure 1 7 Lubricating the de...

Page 290: ... Refer to Figure 1 8 6 Hand tighten the three 3 allen cap screws in the bearing blocks left and right see Figure 1 11 7 Unclip the cable from the capture bar eyelet Push the boom and cable out of the way 8 Remove the 9 16 bolt and washer from the capture bar bracket left and right see Figure 1 6 Figure 1 8 Lowering the bridge into the imagesetter Crane Capture bar brackets Bridge Imagesetter 1 2 3...

Page 291: ...ridge to the imagesetter including the following procedures Attaching the bridge foot Attaching the gas shocks Adjusting the detent plate Attaching and aligning the solid stops Setting up the DEC to bridge buffer interface Attaching the anti static wires 1 5 1 Attaching the Bridge Foot Tools required None Steps 1 Position the bridge foot on the take up platform of the imagesetter Lower the bridge ...

Page 292: ...itting the take up platform opening Refer to Figure 1 10 If a guide block is hitting move the bridge left or right to compensate 4 Check to make certain that the bridge foot lies flat on the take up platform With the bridge up hold a plastic shim on the take up platform at the left rear Lower the bridge onto the shim and try to pull the shim from beneath the foot There should be some resistance If...

Page 293: ...ne of two 5 Also make certain that the bridge bearing blocks top left and right are straight If they are secure to the lower casting by tightening the three 3 allen screws Refer to Figure 1 11 Figure 1 11 Securing the bearing blocks Bearing block Sensor reflector Three allen screws Lower casting 1 1 3 4 2 ...

Page 294: ...wo Spring bolts two of four 1 Screw the threaded end of the gas shock into the bridge mount casting at the top rear of the bridge Refer to Figure 1 13 If necessary lift the bridge to align the ear with the hole in the bridge mount casting 2 Using the spring bolt see Figure 1 12 and nut provided attach the ear to the lower mount casting Refer to Figure 1 13 2 1 ...

Page 295: ...ge mount casting Lower mount casting Gas shock 3 Lower the bridge slowly to make sure that the shocks work 4 Lift the bridge and check the guide block for scuffing see Figure 1 10 Lower the bridge and with a flashlight check again that the guides are not hitting the plate 2 1 3 ...

Page 296: ...dge Button plug one of two 1 5 3 Adjusting the Detent Plate Tools required Screwdriver Steps 1 Open both side doors on the imagesetter by loosening the thumb screws on the inside Refer to Figure 1 15 2 Remove the two 2 plastic access panels at the top of the imagesetter This gives easier access to the detent plates 3 The bridge must be in the down position for this procedure 1 2 ...

Page 297: ...Opening the imagesetter side doors Side door Thumb screw 4 Install the spring plungers loosely left and right Refer to Figure 1 16 Thread the plungers with the ball facing in Figure 1 16 Installing the spring plunger Spring plunger Gas shock 1 2 2 1 ...

Page 298: ...tent plate V groove Adjustment allen screws 7 Back the screw out 1 2 turn 8 Slide the detent plate forward and hold it in place This step preloads the spring plungers which exerts a downward force when the bridge is in the down position 9 Tighten the detent plate adjustment allen screws 10 Lift the bridge halfway so that the plunger ball centers in the detent plate 11 Screw in the spring plunger o...

Page 299: ...2 Put the solid stop pad in the hole in the imagesetter take up platform Refer to Figure 1 18 Figure 1 18 Aligning the solid stops Solid stop pad Put Loctite here left and right Adjustment nuts 3 Close the bridge and put it in heavy mode You can move the shuttle shaft manually if the bridge is not already in heavy mode 4 Screw the solid stop down against the stop pad of the take up platform Refer ...

Page 300: ...l of the imagesetter Refer to Figure 1 19 Figure 1 19 Attaching the bridge buffer interface board Bridge buffer interface board Standoff and nylon washer Interface board cover attach after connectors are in place Four hex screws The interface board should be positioned so that the cable connector appears on the lower right Refer to Figure 1 19 NOTE Do not attach the cover until the connector plugs...

Page 301: ...o Figure 1 20 3 Pass the interface board cable through the left side of the fan housing and connect the cable with the DEC board on the right door Refer to Figure 1 20 Figure 1 20 Routing and connecting the interface board cable DEC Interface board cable bridge buffer board to DEC Interface board Fan housing 2 4 3 1 ...

Page 302: ...h wrap around the cables before they enter the rubber grommet and where they hang near the system casting 8 Install the bridge connectors to the bridge buffer board using the wire and plug designations shown in Figure 1 21 9 Using the four 4 sems screws provided attach the bridge buffer housing cover see Figure 1 19 Figure 1 21 Attaching the connectors to the bridge buffer interface board Bridge b...

Page 303: ...uffer interface board on the left Secure the P clamp to the frame using a sems screw 1 5 6 Attaching the Ground Wires Tools required Screwdriver 1 Remove the sems screw in the P clamp located under the shuttle motor 2 Attach the two 2 ground wires to the bottom of the P clamp Refer to Figure 1 22 Attach the hardware in the following order a star washer b ground cable eyelet c ground cable eyelet d...

Page 304: ...a 36 44 Service Manual 1 22 Installation Figure 1 22 Attaching the ground cables Two ground cables Two star washers P clamp Sems screw 3 Replace the plasic access panels side door top cover rear cover 2 1 3 4 ...

Page 305: ...maging system Because the bridge is internal to the imagesetter the usual long media transport path associated with bridges on line processors is greatly reduced This provides better performance and more reliable operation It also reduces the required floor space by approximately 30 This chapter provides information on the following Information to come ...

Page 306: ...and from the DEC Monitoring takes place while the system runs in normal opera tion mode not service mode The debugger also provides a means for testing var ious components in the bridge buffer area and for checking the status of all the bridge buffer related sensors This chapter provides a detailed description for Setting Up the Debugger Port Bridge Debugger User Interface Terminal Code Identifier...

Page 307: ...dapter cable to interface to the standard serial cable Refer to Figure 3 1 Figure 3 1 Avantra 36 44 Bridge Diagnostic Adapter Cable Use the following parts to interface from a PC to the bridge debugger port 9 pin female connector PC end 78448 015 25 pin male connector imagesetter end 78448 016 cable 78448 008 bridge diagnostic adapter cable C03546 501 15 PIN MALE D TYPE TX RX GND 6 3 2 To Buffer B...

Page 308: ...e prior to sending any normal bridge commands If you attempt commands while the bridge is locked the com mand echoes back preceded by an l Note that the unlock sequence is automati cally sent to the bridge buffer module immediately after system boot up if OLP is enabled UNLOCK Sequence Codes sent from DEC c40 c20 c60 Key Sequence from Terminal SPACE i Bridge Internal State c Command from DEC d Com...

Page 309: ... Cut i2 Center Wait i3 Processor Wait i4 Processor F Sensor Wait i5 Processor Entry Wait i6 Center Clear i7 Buffer Entry Wait i8 Buffer Purchase Wait i9 Buffer to Bridge Clear Wait i10 Bridge Clear i11 Buffer to Processor Wait i12 Processor Purchase Wait i13 Buffer to Buffer Clear i14 Buffer to Bridge Wait i15 Buffer Clear i16 Buffer Home Wait i17 Start Cut Cycle i18 Buffer Exit Wait i19 Start Lon...

Page 310: ... Ready r03 Busy r40 Command Acknowledge r41 Invalid Mode r42 Parameter Out Of Range r43 Invalid Command r44 Command Abort e11 Center not reached e12 Processsor not reached e13 Center not cleared e14 No lower encoder e15 No upper encoder e16 No media to take e17 Buffer entry sensor not reached e18 Buffer purchase sensor not reached e1A Bridge not cleared e1B Processor not reached by buffer e1C Buff...

Page 311: ...sors 2 rows are located in a separate byte Row 1 5 bits is located in the lower byte row 2 5 bits is located on the upper byte Sensors Located On Row 1 Lower or Second Byte Sensors Located On Row 2 Upper or First Byte 0001 Actuator Sensor 0002 Loop Sensor 0004 Bridge Purchase Sensor 0008 Shuttle Bridge Mode Sensor 0010 Shuttle Cassette Mode Sensor 0100 Unused Sensor 0200 Buffer Entry Sensor 0400 B...

Page 312: ... the bridge buffer module via the terminal by typing in the approriate key sequence The following lists com mand numbers key sequences and description of available bridge buffer com mands A c precedes the bridge buffer commands if the command was sent from the DEC A d precedes if the command was sent from the debug terminal 0 Nominal speed 1 Max Torque 2 Steps to Processor 3 DC Motor Speed 4 Stepp...

Page 313: ...Processor OFF l 0C Bridge Slow Speed m 0D Bridge Fast Speed n 0E Buffer Roller Fast Speed o 0F Buffer Roller Slow Speed p 10 Set Parameter q 11 Short Feed r 12 Soft Reset s 13 Get Parameter t 14 Move Shuttle to Light Mode u 15 Move Shuttle to Heavy Mode v 16 Shuttle OFF w 17 Brake ON CW x 18 Brake ON CCW y 19 Brake OFF z 1A Move Carriage to Bridge Buffer 1B Move Carriage to Processor Buffer 1C Car...

Page 314: ...ures used when removing and replacing components in the bridge The following topics describe the required sequence Removing and Replacing the Bridge Foot Media Purchase Sensor Bridge Loop Sensor Upper Bridge Servo Motor The Activator Switch The Bridge Up Sensor Bridge Shuttle Motor Shuttle Light and Heavy Sensors ...

Page 315: ... position and in heavy mode 2 Unscrew the two 2 thumb screws one on each side of the foot Refer to Figure 4 1 Figure 4 1 Bridge foot Foot face plate Six three each side face plate screws Two thumb screws Media purchase sensor connector Loop sensor connector 3 Lift the bridge and pull the foot out Replace 1 Reverse the procedures above 2 1 2 3 5 4 ...

Page 316: ...e 4 1 3 Using a 3 16 allen wrench remove the holding screw Replace 1 Reverse the procedure above 4 4 Bridge Loop Sensor Tools Phillips screwdriver 5 16 open end wrench Remove 1 Remove the six 6 screws three 3 on each side of the bridge foot face plate Refer to Figure 4 1 2 Remove the bridge loop sensor connector Refer to Figure 4 1 3 Using a 5 16 open wrench remove the holding nut Replace 1 Revers...

Page 317: ...r on the right Refer to Figure 4 2 Figure 4 2 Bridge side cover Bridge Side cover Electrical connector Six side cover screws Upper bridge servo motor 3 Remove the electrical connector Refer to Figure 4 2 4 Remove the female connector from the other side of the cover Refer to Figure 4 3 5 Remove the connector from the bridge up sensor to release the side cover Refer to Figure 4 3 Move the cover awa...

Page 318: ...ar Refer to Figure 4 3 9 Remove the gear from the motor Refer to Figure 4 3 Figure 4 3 Bridge side cover exposed view Drive belt Tensioner assembly Upper bridge servo motor Motor power connectors red and brown Servo motor gear with allen screws Two servo motor mounting hex screws Side cover Bridge up sensor Side cover electrical connector Replace 1 Replace the gear on the motor 2 Reverse the proce...

Page 319: ...rewdriver remove the three 3 cover screws Refer to Figure 4 4 2 Disconnect the switch connectors Refer to Figure 4 4 3 Using a flathead screwdriver remove the two switch mounting screws Refer to Figure 4 4 Figure 4 4 Activator switch Cover Three cover screws Switch connectors Two switch mounting screws Activator switch Replace 1 Reverse the procedures above 1 2 3 5 4 ...

Page 320: ...six 6 holding screws from the bridge side cover on the right Refer to Figure 4 2 3 Remove the connector from the bridge up sensor Refer to Figure 4 5 4 Remove the sensor connector Refer to Figure 4 5 5 Using a 1 4 open end wrench remove the two 2 nuts securing the sen sor to the cover Refer to Figure 4 5 Figure 4 5 Bridge up sensor Bridge up sensor Side cover Securing nuts Sensor connector Replace...

Page 321: ... the left Refer to Figure 4 6 3 Put the bridge in the down position to remove the two 2 remaining allen head screws on the front of the cover Refer to Figure 4 6 4 Remove the two 2 power connectors from the bottom of the motor Note the wire positions for replacement Refer to Figure 4 6 Figure 4 6 Bridge shuttle motor Bridge shuttle motor cover Three allen screws Tie wraps Bridge shttle motor Two p...

Page 322: ...e two 2 motor mounting screws Refer to Figure 4 7 Figure 4 7 Motor mounting screws and coupling Anti static cable Shaft Cover Coupling Two mounting screws Replace 1 Reverse the above procedure 2 Put the system through a practice run to make certain that the motor runs properly 3 4 5 2 1 ...

Page 323: ...igure 4 8 Shuttle light and heavy sensor assembly Bridge shuttle motor Cover Shuttle light and heavy sensor assembly Two mounting screws Two sensor assembly connectors 2 Remove the two 2 sensor connectors Refer to Figure 4 8 3 Remove the single screw securing the sensors in place Replace 1 Reverse the above procedures 2 Put the system through a practice run to make certain that the sensors run pro...

Page 324: ...iver servo motor AV36 44 36S 44S 066481 005 Bridge shuttle DC gear motor AV36 44 36S 44S 066719 001 Slack loop sensor AV36 44 36S 44S 066719 001 Shuttle position sensors AV36 44 36S 44S 066721 002 Bridge foot purchase sensor AV36 44 36S 44S 065938 001 Bridge foot micro switch AV36 44 36S 44S 056461 084 Bridge timing belt AV36 44 36S 44S 066393 001 Bridge up sensor AV36 44 36S 44S Depends on the so...

Page 325: ...ting 1 13 Bridge Parameters 3 7 Bridge Sensor Status 3 6 Bridge Shuttle Motor 4 8 Bridge State Responses 3 5 Bridge States 3 4 Bridge Unlock Sequence 3 3 Bridge Up Sensor 4 7 Bridge Aligning 1 11 Bridge Attaching the Capture Bar 1 5 Bridge Attaching to Imagesetter 1 9 Bridge Raising and Lowering into Imagesetter 1 7 Bridge Buffer Commands 3 7 Bridge Buffer Interface Board 1 20 Bridge buffer Interf...

Page 326: ... O Opening Side Doors 1 14 Operation Mode 3 1 P Parameters Bridge 3 7 Placing the Button Plugs 1 14 Procomm 3 2 R Raising the Bridge 1 7 Removing and Replacing the Bridge Foot 4 2 Removing the Imagesetter Top Cover 1 2 Responses Bridge State 3 5 Routing the Interface Board Cable 1 19 S Sensor bridge loop 4 3 bridge up 4 7 media purchase 4 3 shuttle light and heavy 4 10 Sensor Request Command F 3 6...

Page 327: ...Section III Buffer ...

Page 328: ...ction This chapter provides information for unpacking unlocking and installing the Avantra 36 44 buffer Included in this chapter are Buffer Installation Procedures Unpacking the Buffer Unlocking the Buffer Installing the Buffer to the Imagesetter ...

Page 329: ...ships in a single cardboard box attached to a wooden pallet see Figure 1 1 Tools Strap cutters 7 16 hex wrench 9 16 hex wrench Steps 1 Cut the two 2 straps around the cardboard sleeve and remove the top cardboard cover Refer to Figure 1 1 Figure 1 1 The buffer shipping box Box cover Shipping straps 2 Shipping box 1 3 2 ...

Page 330: ...r to Figure 1 2 3 Lift the cardboard sleeve straight off the pallet 4 Cut the shipping straps going around the unit frame Refer to Figure 1 2 These straps hold the unit s top cover in place Figure 1 2 Removing the box spacers and straps Foam spacers 2 Box cover Shipping straps 2 2 3 1 ...

Page 331: ...outriggers at the rear of the unit only 6 Using a 9 16 hex wrench remove the two 2 bolts from the bottom left and two 2 bolts from the bottom right of the pallet Refer to Figure 1 3 7 Remove the anti static bag covering the unit Figure 1 3 Removing the rear outriggers and pallet bolts Shipping strap Two rear outriggers Two 7 16 hex outrigger bolts Pallet bolts located under unit 4 2 1 3 4 ...

Page 332: ...straight out Refer to Figure 1 4 CAUTION The side panels attach to the unit by means of a lock pin at each of the four corners Do not tilt the side panels or the lock pins could bend or snap WARNING Four persons must be used for lifting the unit Figure 1 4 Removing the side panels Top cover Side panels 2 1 ...

Page 333: ...top cover on the unit is not attached and will come off 10 Replace the side panels at the bottom of the unit frame Refer to Figure 1 4 CAUTION Do not force the side panels back into place Doing so could bend and break the lock pins 1 2 2 Unlocking the Buffer The buffer comes with a kit for preparing the unit Check the kit s contents against the hardware shown in Figure 1 5 Figure 1 5 Hardware for ...

Page 334: ...ation 1 7 Steps 1 To unlock the buffer carriage remove the two 2 shipping screws from the top rear of the buffer Refer to Figure 1 6 Figure 1 6 Unlocking the carriage lock bolts Buffer carriage lock bolt 1 of 2 left and right 1 ...

Page 335: ...a 36 44 Service Manual 1 8 Installation 2 Insert the plastic plugs see Figure 1 5 in the two 2 shipping screw holes Refer to Figure 1 7 Figure 1 7 Placing the plastic plugs and foam pads Plastic plug 1 of 2 1 ...

Page 336: ...buffer input platen remove the two 2 lockdown bolts The lockdown bolts are located on the left and right portion of the platen near the hinge screws Refer to Figure 1 8 Figure 1 8 Removing the platen lockdown bolts Platen Platen lockdown bolt 1 of 2 2 1 ...

Page 337: ...ed in Figure 1 9 Figure 1 9 Accessories for attaching the imagesetter to the buffer and for imagesetter installation Chafe tray Extension platen Nuts for attaching the side plates to the platen and the brackets to the imagesetter frame Side plates Brackets The extension platen and related hardware are used when attaching the imageset ter to the buffer The chafe tray is inserted as part of the imag...

Page 338: ...gure 1 10 and Figure 1 11 Figure 1 10 Inserting the extension platen at the rear of the imagesetter Exit platen opening Imagesetter rear with back panel removed Extension platen assembly 4 Attach the left and right brackets to the side plates using the nuts provided Refer to Figure 1 10 and Figure 1 11 NOTE Keep the nuts loose on the side plates and brackets so that the extension can be easily shi...

Page 339: ...from the imagesetter frame 9 Remove the imagesetter plastic access panels left and right to get at the studs and brackets Attach the brackets left and right to the studs using the two 2 nuts provided Refer to Figure 1 11 Figure 1 11 Attaching the extension platen to the imagesetter Inside rear of imagesetter Extension platen brackets One of two imagesetter access covers left and right Hex nuts att...

Page 340: ...d the edge of the extension platen 11 Lower the bridge 12 Slide the extension platen toward the bridge Using the two 2 platen alignment pins provided align the holes on the bottom of the bridge platen left and right with the holes in the extension platen Refer to Figure 1 12 Figure 1 12 Aligning the bridge platen and extension platen Imagesetter Alignment hole on the extension platen One of two al...

Page 341: ... align loosen the nuts and repeat Steps 11 and 12 14 Place the labels provided over the top of the extension platen alignment holes The labels prevent light leakage 15 Move the buffer against the imagesetter The imagesetter extension platen should fall within the buffer platen 16 Screw the buffer leveling feet about one full turn so that the buffer is flat against the imagesetter Align the mountin...

Page 342: ...tter leg adjustment screws 17 Secure the buffer to the imagesetter using the two 2 10 32 x 1 4 sems screws one at each end of the buffer platen at the top corners The screws pass through the buffer platen from the inside and into the threaded inserts at the back of the imagesetter Refer to Figure 1 14 3 4 1 2 5 ...

Page 343: ... 18 Open the right side door on the imagesetter See the Avantra 36 44 Image setter Service Manual Chapter 4 Section 4 2 1 Right Left Side Covers 19 Remove the black plastic plug located at the bottom and inside rear of the imagesetter 20 Open the lower right panel on the buffer by pulling the panel straight out see Figure 1 4 1 2 3 ...

Page 344: ...s hole Refer to Figure 1 15 The harness hole is located on the right hand side of the buffer at the front and near the bottom Figure 1 15 Routing the buffer harness cable through hole right bottom inside front Wire bundle 22 Route the wire bundle through the rubber gasket and into the imagesetter Refer to Figure 1 15 1 ...

Page 345: ...s shown in Figure 1 16 Figure 1 16 Attaching the buffer wires to the buffer imagesetter interface board Buffer to Imagesetter harness opening Connector Connector Connector Connector Interface board NOTE See the Avantra 36 44 OLP Service Manual for the OLP attachment procedures and for attaching the anti static wire 6 4 3 5 2 1 ...

Page 346: ...he imagesetter of the buffer Hold the carriage tightly against the frame If both ends of the carriage are flush against the frame nothing else is required If the carriage is not flush go to Step 3 3 For older buffers a Remove the four 4 screws in the braces on the left and right hand side of the buffer Refer to Figure 1 17 Lift the braces off Figure 1 17 Older buffer brace Endbrace Fourendbracescr...

Page 347: ...ervice Manual 1 20 Installation For newer buffers b The braces will have access holes and will not need to be removed Refer to Figure 1 18 Figure 1 18 Newer buffer brace End brace Access holes to alignment screws 1 2 ...

Page 348: ...top of the rail bearing block Refer to Figure 1 19 Figure 1 19 Buffer carriage adjustment screws Access holes in braces Adjustment screws four on each end Buffer carriage move to the front for adjustment 5 Straighten the carriage so that it is flush with the frame and tighten the adjustment screws 3 2 1 ...

Page 349: ...This chapter describes the procedures for removing and replacing components in the Avantra 36 44 buffer Topics covered are Buffer Home and Buffer Processor Sensors Buffer Purchase Sensor Buffer Carriage Drive Motor Buffer Roller Driver Motor Aligning the Buffer Carriage ...

Page 350: ...fer processor sensors Tools Required 1 4 open end wrench Remove 1 Remove the top cover from the buffer 2 Disconnect the connector s from the sensor s Refer to Figure 2 1 for identification 3 Remove the 1 4 hex nuts securing the sensors Figure 2 1 Buffer sensors and flags Sensor flags Home sensor bottom and buffer processor sensor top with connectors Buffer carriage 3 1 2 ...

Page 351: ... Purchase Sensor The following describes how to remove and replace the purchase sensor Tools Required 1 4 open end wrench Remove 1 Remove the top cover from the buffer 2 Disconnect the connector from the sensor Refer to Figure 2 2 3 Remove the two 2 1 4 hex nuts securing the sensor Figure 2 2 Buffer purchase sensor Carriage drive motor Lead screw Buffer purchase sensor Replace 1 Reverse the proced...

Page 352: ... the four 4 screws from the brace located in the top center of the buffer Refer to Figure 2 3 Figure 2 3 Carriage drive motor cover Four cover mounting screws Carriage drive motor cover Carriage drive motor Lead screw 3 Remove the two 2 screws on the motor bracket Refer to Figure 2 4 4 Using a flathead screwdriver disconnect the two 2 P clips attached to the bracket Refer to Figure 2 4 5 Cut the t...

Page 353: ...everse the procedures above 2 5 Buffer Roller Driver Motor The following describes how to remove and replace the buffer roller driver motor Tools Required 1 4 open end wrench Remove 1 Remove the top cover from the buffer 2 Remove the top side panels 3 Pull the two power plugs from the driver motor NOTE Make note of the positioning of the two power plugs red and brown for purposes of replacement 4 ...

Page 354: ...g screws Drive motor allen screw Drive gear 4 Pull the encoder plug from the motor 5 Remove the four 4 1 4 screws two 2 on each side securing the motor Refer to Figure 2 5 6 Cut the tie wrap holding the wires to the motor 7 Remove the three 3 3 16 motor mounting screws from the back of the motor bracket Refer to Figure 2 5 8 Remove the set screw from the gear Refer to Figure 2 5 1 3 2 6 4 5 ...

Page 355: ...and Replacement 2 7 Replace 1 Reverse the removal procedures above 2 When re attaching the motor gear make sure that it matches up correctly with the roller gear Using your fingers spin the roller to check that the two gears mesh ...

Page 356: ...servo 067338 001 Motor stepper shaft 066721 002 Sensor buffer entrance 066271 002 Sensor buffer purchase 066719 001 Sensor buffer home proc 067326 001 Brake C02395 001 Buffer top cover C02328 001 Buffer top side cover C02330 001 Buffer bottom side cover ...

Page 357: ...Feet 1 14 Buffer Platen 1 14 1 15 Buffer Processor Sensor 2 2 Buffer Purchase Sensor 2 3 Buffer Roller Driver Motor 2 5 Buffer to Imagesetter Installation 1 10 Buffer Imagesetter Interface Board 1 18 C Chafe Tray 1 10 E Exit Platen 1 11 Extension Platen 1 10 1 11 1 12 1 13 1 14 alignment holes 1 14 brackets 1 14 Extension Platen Brackets 1 12 I Imagesetter alignment holes 1 13 back panel removal 1...

Page 358: ...Index buffer processor 2 2 buffer purchase 2 3 Side Panels 1 5 U Unlocking buffer carriage 1 7 buffer input platen 1 9 carriage lock bolts 1 7 plastic plugs 1 8 Unlocking Kit Buffer 1 6 Unlocking the Buffer 1 6 Unpacking the Buffer 1 2 ...

Page 359: ...Section IV On line Processor ...

Page 360: ...ontains OLP Work Space Requirements Space Floor Load Electrical Operational OLP Unpacking Procedures Tools Required for OLP Unpacking OLP Inventory Opening and Unpacking the Parts Crate Unpacking and Preparing the OLP Engine Installation Procedures Attaching the Legs and Feet Connecting the Water Supply and Drainage Connecting the Interface Cable Connecting The Electrical Supply Leveling and Attac...

Page 361: ... cm including receiver tray sheet mat Buffer Dimensions Width 61 24 cm Height 54 21 25 cm Length 15 6 cm Imagesetter Dimensions Width 73 29 cm Height 48 19 cm Length 35 14 cm 1 2 2 Floor Load OLP Weight Net Weight 937 lbs 2066 kg Oper Wt 1136 lbs 2505 kg Buffer Weight Weight 200 lbs 441 kg Imagesetter Weight Weight 1700 lbs 3748 kg 1 2 3 Electrical OLP Electrical Volts 208 240 VAC Hertz 50 60 Hz P...

Page 362: ...umption 0 5 US Gal 0 2 L min 1 3 OLP Unpacking Procedures 1 3 1 Tools Required for OLP Unpacking Crowbar Claw hammer Strap cutters 1 3 2 OLP Inventory The Avantra 36 44 OLP arrives in two crates The top crate contains the OLP parts including 1 Receiver basket 1 of 2 2 Receiver basket 1 of 2 3 Rear exit panel bottom 4 Middle top cover 5 Rear exit panel top 6 Rear top side panel 7 Rear top side pane...

Page 363: ...ver 17 Panel between imagesetter and OLP 18 Top cover rear 19 Chemistry trolley 20 Drip tray 1 of 2 21 Rack drip tray 22 Filter parts chemical bottle covers etc 23 Fixer rack 24 Developer rack 25 Wash rack 26 Developer fixer crossover guide 27 Fixer wash crossover guide 28 Anti oxidation cover 1 of 2 29 Anti oxidation cove 2 of 2 30 Stabilizer cross member for legs 12 The bottom crate contains the...

Page 364: ... site where the OLP is to be installed If this is not possible unpack remove and transport the parts according to the followings steps 2 Using strap cutters cut the straps from around the wooden crate 3 Using a crowbar and claw hammer open the crate 4 As the parts are removed check them against the inventory list at the beginning of this section and in Figure 1 2 1 2 Parts Container Engine Contain...

Page 365: ...5 Lower front covers for entrance rack 2 16 Inner cover for entrance rack under forward top cover 17 Front panel 18 Rear top cover 19 Chemistry trolley 20 Drip tray 21 Rack drip tray 22 Filter parts chemical bottle covers etc 23 Developer rack 24 Fixer rack 25 Wash rack 26 Developer fixer crossover guide 27 Fixer wash crossover guide 28 Developer anti oxidation cover 29 Fixer anti oxidation cover ...

Page 366: ...should be transported through mechanical means 5 Load the three 3 cardboard boxes containing the racks onto a separate pallet Cover the boxes with cardboard Figure 1 3 Rack boxes 6 Load the legs on top of the cardboard and with a forklift take the pallet to the installation site Figure 1 4 OLP legs ...

Page 367: ...OLP is to be installed If this is not possible unpack remove and transport the OLP engine according to the followings steps 2 Using strap cutters cut the straps from around the wooden crate 3 Using a crowbar and claw hammer open the crate 4 Remove the cardboard cover and the plastic cover Figure 1 5 Engine crate Bottom shipping crate Engine packing 1 2 ...

Page 368: ... front of the engine remove the roller and bearing on top Refer to Figure 1 6 6 At the rear of the engine tape the door securely to the frame Refer to Figure 1 6 Figure 1 6 Engine lid and roller Lid tape before moving engine Roller remove before moving 1 2 ...

Page 369: ...located on the side of the engine and tape them to the inside of the frame Refer to Figure 1 7 8 Using a phillips head screwdriver remove the chimney with fan attached and tape them to the inside of the frame Refer to Figure 1 7 Figure 1 7 Open door sensors and fan Sensor 1 of 2 with screws Fan attached to chimney 2 1 ...

Page 370: ...n open ended wrench remove the four 4 shipping standoffs securing the OLP engine frame to the bottom of the crate The standoffs are located at the four corners of the frame Refer to Figure 1 8 Figure 1 8 Standoffs Bottom of crate Shipping standoff 1 of 4 2 1 ...

Page 371: ... the wheels then tip the OLP engine onto its side and lift onto the dollies Refer to Figure 1 9 WARNING Always use proper back support belts when lifting heavy weights see Figure 1 10 Figure 1 9 Engine assembly loaded on dollies Engine assembly Transport dollies 11 Bring the engine to the installation site 2 1 ...

Page 372: ...cury type Adjustable open end wrench 500 ml graduate 1 5 1 Attaching the Legs and Feet NOTE Do not remove the engine from the dollies until the legs lev eler feet two at the top and stabilizer bar are attached to the frame 1 Using a hex driver attach the two 2 legs to the bottom of the OLP engine frame Refer to Figure 1 10 and Figure 1 11 Attach the lower bolts first followed by the upper ones Thi...

Page 373: ...he legs on a block and install the remaining two 2 leveler feet Refer to Figure 1 10 and Figure 1 11 WARNING Always use proper back support belts when lifting heavy weights see Figure 1 10 5 Reattach the sensors to the side of the frame see Figure 1 7 6 Reattach the chimney with fan to the side of the frame see Figure 1 7 Figure 1 10 Tipping the OLP engine Front leveler feet attach first before ti...

Page 374: ... after developing and fixing the processor must be connected to temperate wash water The water temperature must not exceed 110 F 43 C and the water pressure must be 0 3 bar to 10 bar Filtration rate of the filter cartridge should be at least 25 microns CAUTION The temperature difference between the fixer and the water in the wash section must not exceed 27 F 15 C Exceeding this temperature may cau...

Page 375: ...ain fit tings on the bottom of each tank Using the stainless steel clamps pro vided secure the hoses to the fittings Securing the hoses prevents leakage Installing the Interface Cable 1 Remove the back and rear side panels of the OLP if they are not already off 2 Connect the interface cable at X402 3 Route the new cable in place through the processor 4 Route the cable into the imagesetter electron...

Page 376: ...ing the RJ45 to DB9 adapter 7 Check that the cable does not interfere with other components when clos ing the cabinet doors 1 5 3 Connecting The Electrical Supply CAUTION Electrical connections and sources must comply with local electrical codes Power Supply 208 240 VAC 50 60 Hz 1 2 or 3 phases neutral ground see electrical connection Load Max 7 0 kW operational mode 0 4 kW stand by mode ...

Page 377: ...en 220 and 240VAC leave the connection as is 5 220VAC If the supply voltage measures below 220VAC disconnect the wire from the 5 position 220VAC and reconnect it to the 4 position 200VAC Operation on 400 415V 3N 50 60HZ The processor is wired at the factory for operation on 400 415V 3N 50 60Hz plus ground line See the top connection diagram in Figure 1 14 below If this is the available power sourc...

Page 378: ... 2 29 3 3 1 15 2 29 3 4 F6 F5 F4 F3 F2 F1 N3 N2 N1 N4 F106 F105 F104 F103 F102 F101 L3 L2 L1 208 240V 3 PH 50 60HZ FUSE AMP 101 10 102 10 103 15 104 10 105 15 106 10 230 240 VAC 14 2 21 7 3 1 2 2 12 1 2 230 240 VAC 14 0 24 8 4 F6 F5 F4 F3 F2 F1 N3 N2 N1 N4 F106 F105 F104 F103 F102 F101 L2 L1 N 400 415V 2 N 50 60HZ FUSE AMP 101 6 3 102 10 103 10 104 2 105 15 106 400 415 VAC 2 2 6 4 3 1 2 230 240 VA...

Page 379: ...fixer tank 2 For front to back leveling use the spirit level along the top of the tank side walls 3 Attach the front panel Refer to Figure 1 15 Figure 1 15 Attaching covers and panels to the OLP Front left vent cover Front right vent cover Lower rear panel Left side panel Front panel 4 Remove the block of wood and bolt shipping hardware from the entrance rack assembly at the front of the OLP 3 2 1...

Page 380: ...ck Refer to Figure 1 16 6 Roll the imagesetter with the buffer attached to the OLP The buffer and OLP must interface as shown in Figure 1 16 Figure 1 16 The buffer and OLP interface Buffer interface OLP front plate Lower platen of entry rack Upper platen removed during the interface alignment 1 2 4 3 ...

Page 381: ...e imagesetter buffer and OLP in close proximity measure the distance from the floor to the buffer exit platen and the floor to the OLP entrance platen Refer to Figure 1 17 Figure 1 17 Measuring from the floor to the platen for correct OLP To Buffer Alignment OLP entrance platen Buffer exit platen 1 2 ...

Page 382: ... Refer to Figure 1 18 9 Push the buffer attached to the imagesetter flush against the OLP 10 Lower the feet at the front of the imagesetter to hold the imagesetter buffer assembly tightly against the OLP Figure 1 18 Adjusting the buffer legs for buffer to OLP alignment OLP Adjustable leg Buffer Imagesetter Leg adjustment screw 3 4 1 2 5 ...

Page 383: ... 1 on each side to the front of the OLP engine Refer to Figure 1 19 2 Attach the lower rear panel Refer to Figure 1 19 3 Attach the left side panel bottom Refer to Figure 1 19 Figure 1 19 Front rear and side panels Front left side cover Front right side cover Lower rear panel Left side panel bottom 4 Attach the developer filter on the left side 3 2 1 4 ...

Page 384: ... side of the frame Refer to Figure 1 20 7 Attach the left lower door hinged to the right side of the frame Refer to Figure 1 20 8 Attach the right lower door hinged to the right side of the frame Refer to Figure 1 20 Figure 1 20 Side covers striker plate doors for right side Top left side panel Bottom left side panel Striker plate Right side hinged doors 2 1 4 2 3 ...

Page 385: ... Place the drip tray trolley and fluid containers under the OLP Refer to Figure 1 21 Figure 1 21 Placing the drip tray chemistry trolley and fluid containers Drip tray Chemistry trolley Fluid containers 11 Underneath the engine cut the tie wraps for the red developer hose blue fixer hose grey water supply hose black and white wires replenishment sensors 3 1 2 ...

Page 386: ...lly CAUTION Installing the racks in the next step requires two people unless the crane is installed If two people are not available at this step in the installation seeThe Avantra 36 44 Crane Service Manual Chapter 1 Installing the Crane 13 Put the racks in in the following order a developer b fixer c wash Refer to Figure 1 22 Figure 1 22 Racks Developer Fixer Wash 1 2 3 ...

Page 387: ...op front of the engine Refer to Figure 1 23 5 Check for a proper mesh between the main drive worm gears and the cor responding gears on each rack Figure 1 23 Replacing the roller Right side cover Roller replace 6 Plug in the power cord at the rear of the engine 7 Attach the back panel 1 2 ...

Page 388: ... IV On line Processor Installation 1 29 8 Attach the basket 2 parts at the rear Refer to Figure 1 24 Figure 1 24 Rear panel and media basket Rear panel Media basket assembly 26 Put in the two 2 crossovers 1 2 ...

Page 389: ...Blue for fixer Grey for water Refer to Figure 1 25 Figure 1 25 Overflow supports and tubes Overflow supports Overflow tubes 28 Check that the overflow tubes are secure by tightening with a T wrench 29 Re tighten all hose clamps 30 Check that the valve at the bottom of the developer filter housing is closed and the valves leading to and from the filter housing are open 31 Fill each tank with water ...

Page 390: ...or to warm up to operating temperature check the sys tem for possible leaks 38 Feed a piece of media through the processor to confirm proper transport 39 Check transport speed as follows a Refer to the calibration procedure b Enter service code 112 c Compare the preset motor speed value to the actual value d If the values do not correspond proceed with the motor calibration procedure 42 Turn the p...

Page 391: ... replenishment containers 49 Replace the overflow tubes racks crossover guides and lids 50 Put in the two 2 anti evaporation covers stainless steel inside the racks Next place the front cover and the two 2 anti oxidation covers Refer to Figure 1 26 Figure 1 26 Anti evaporation front and anti oxidation cover locations Anti evaporation covers Forward top cover Anti oxidation covers 2 3 1 ...

Page 392: ...ne Processor Installation 1 33 51 Put in the middle and rear anti oxidation covers plastic over the racks Refer to Figure 1 27 Figure 1 27 Evaporation covers over racks Middle evaporation cover over fixer Developer 1 2 ...

Page 393: ...4 Service Manual 1 34 Installation 52 Put the Top Covers on in the following order middle forward front rear Refer to Figure 1 28 Figure 1 28 Top covers Forward front top cover Middle top cover Rear top cover 1 2 2 ...

Page 394: ...ors OLP racks including the methods of replenishment This chapter contains the following information Description of OLP Boot up Procedures OLP Standby Mode Idle Mode Ready Mode Operate Mode The OLP Jog Function Electronics4 The LUTH Computer Board LCB The LUTH Power Board LPB The LUTH Motot Board LMB The Agfa Terminal Board ATB Sensors OLP Racks Temperature Control Replenishment ...

Page 395: ... Temp Incorrect LED flashes As long as the temperature remains inaccurate the OLP cannot start by activating the film input sensors by pressing MAN START or the Dryer Saver key As soon as the developer temperature equals the preset temperature the processor switches to Ready mode and the Dev Temp Incorrect LED stops flashing 2 2 3 Ready Mode When all preset parameters have been ahieved and the tan...

Page 396: ...n run continuously until the Man Start key is deactivated When the correct level is reached the processor switches to Ready mode or if the developer temperature is now inaccurate to Idle mode 2 2 5 The OLP Jog Function In order to avoid crystallization on the rollers in the developer and fixer racks the processor automatically and at preset intervals starts the main motor for the transport rollers...

Page 397: ...log input A software controlled amplifier gives impedance matching to sensors of platinum type PT500 used for measur ing developer fixer dryer temperatures The amplifier limits the operating area between 0 and 100 C The exit sensor channel only for OLP channel is a digital input Connections 1 6 connected to P30 exit sensor only for OLP 3 7 connected to P16 dryer temperature sensor 4 8 connected to...

Page 398: ...e LPB X1 5 control the K8 Dev repl pump 3 connected to the LPB X1 6 control the K7 Dryer fan and basic heat 4 connected to the LPB X1 7 not used Q5 5 connected to the LPB X1 8 control the Q3 Fix heat 1500W 7 connected to the LPB X1 10 control the Q1 Dev heat 1500W 8 connected to the LPB X1 11 control the K12 Drive motor 10 connected to the LPB X1 2 control the K11 Circ pumps 11 connected to the LP...

Page 399: ... terminals Switched output to water solenoid valve heating elements blower circulation replenishment pumps main motor and step down transformer 2 3 2 The LUTH Power Board LPB The Luth Power Board switches the necessary 2230V components on and off The LPB pcb includes Five long life zero cross Triac channels only four are used Seven power relays with noise suppression circuits aross the contacts on...

Page 400: ... dryer fan basic heat 7 not used 8 from X200 5 input to Q3 1500W fix heater 9 not used 10 from X200 7 input to Q1 1500W dev heater 11 from X200 8 input to K12 prim 24V trafo LMB02 12 input to Q6 via X7 2 dryer heat 2 13 from X200 18 Gound Optocoupler pcb diode X2 1 2 Front and top lids safety switches front safety switch exists only on the latest OLP version 2 Optocoupler pcb diode to X501 12 25 X...

Page 401: ...ta Description of Inputs and Outputs 1 2 Data communication link between the LCB and the Agfa Terminal Board ATB RS 232 serial data coded as ASCII characters are interchanged 2 3 5 Sensors Optical Interrupter This device consists of a transmissive sensor with four 4 wires and connectors The operating wavelength is 950 nm The detec tor is a Photologic IC with Schmitt Trigger output Aperature size i...

Page 402: ...t Automatic replenishment keeps the concentration of developer and fixer chemistries at a contant level This procedure adds chemistry to compensate for that lost during processing A description of the procedure follows The processor pumps a constant 100cc of developer and fixer replenishment liquid into the tanks A calculation based on the preset replenishment value the area of the material and th...

Page 403: ... on the control panel for more than 30 minutes the topping up replenishment function automatically comes on This procedure pumps one litre of developer and one litre of fixer into the baths If this action offsets the low level condition the processor will be ready the next time it is switched on If the action fails to offset the low level condition the system goes to low level mode jog mode stops ...

Page 404: ...sor OLP This chapter contains information about the Drive Motor CPU OLP LUTH Motor Control Board LUTH Rectifier Board LRB Power Board Circulation Pump Developer or Fixer Replenishment Pumps Heating Element Wet Section Temperature Sensor Dryer Section Temperature Sensor Dryer Blower Motor Assembly Dryer Heater Element Dryer Blower Entry Rack Assembly Drive Belt Drive Shaft ...

Page 405: ... Remove 1 Turn off and unplug the OLP 2 Remove the side panel at the top left 3 Using a phillips screwdriver remove the bracket with the encoder sensor sensor connector attached Refer to Figure 3 1 Figure 3 1 The drive motor Drive wheel set screw Drive wheel Drive belt Idler Three mounting bolts Encoder disk Encoder sensor sensor connector Drive motor Drive motor power connectors M1 M2 5 4 2 3 1 6...

Page 406: ...ce using three 3 mounting bolts Do not tighten 2 Reattach the belt wheel and encoder disk to the end of the shaft 3 Replace the belt around the idler and belt wheel 4 Adjust the motor and motor mount to achieve the proper belt tension Ideally the belt should not be too tight or too loose Allow for a 1 4 deflection left and right of center 5 Reconnect the two 2 power connectors M1 on the left and M...

Page 407: ...p back panel 4 Pull the electronics box straight out on its rollers 5 Remove the seven cable plugs at the rear of the box Refer to Figure 3 2 6 Remove all fourteen 14 standoffs at the rear of the box Refer to Figure 3 2 Figure 3 2 The electronics box with rear standoffs and connectors CPU electronics box Seven connectors and fourteen standoffs X503level and feedback X501 film sensors X502 Startbox...

Page 408: ... and Replacement 3 5 7 Using a phillips screwdriver remove the four 4 hinge screws at the rear of the box Remove the four central screws only Refer to Figure 3 3 Figure 3 3 Electronics box rear screws Electronics box Four rear screws 2 1 ...

Page 409: ...he top and the two 2 screws on each side of the box Refer to Figure 3 4 9 Open the top of the box and disconnect the a Low voltage CPU power connector b Power board cable Refer to Figure 3 4 Figure 3 4 Electronics box side top screws and power cables Side screws Four top screws Low voltage and CPU power cables 1 1 2 3 ...

Page 410: ... 10 Remove the three 3 phillips screws securing the inner cover Refer to Figure 3 5 11 Remove the six 6 standoffs at the rear Refer to Figure 3 5 Remove the cover Figure 3 5 CPU cover screws and standoffs Three CPU cover screws CPU cover Six standoffs 1 2 3 ...

Page 411: ...nnectors and mounting screws Low voltage connector Power cable connector Lithium battery Fahrenheit Centigrade jumper EEPROM CPU fuse connectors Three mounting screws Replace 1 Reverse the steps in the removal procedure above NOTE Check the battery on the new CPU and remove the paper if present between the battery and ground retaining clip check and adjust the temperature display mode jumper to th...

Page 412: ...7 3 Remove the connectors at X6 and X2 Refer to Figure 3 7 NOTE Note the position of the power connectors for replacement 4 Using a needle nose pliars release the two 2 nylon standoffs from the front of the board Refer to Figure 3 7 5 Using a phillips screwdriver remove the mounting screws at the rear Refer to Figure 3 7 Figure 3 7 The LUTH motor control board Motor control board Two rear mounting...

Page 413: ...he jumper settings Refer to Chapter 4 OLP Maintenance 5 Perform the motor speed calibration Refer to Chapter 4 OLP Maintenance 3 5 LUTH Rectifier Board LRB Tools Required Needle nose pliars small flathead screwdriver Remove 1 See the removal procedures in Section 3 3 CPU OLP for exposing the board 2 Using a small flathead screwdriver remove the wires from the two 2 ter minal blocks on the bottom o...

Page 414: ... Reverse the steps in the removal procedure above CAUTION Be careful to return the wires to their proper places in the terminal blocks 3 6 Power Board The following describes how to remove and replace the power board Tools Required Phillips screwdriver small flathead screwdriver Remove 1 See the removal procedures in Section 3 3 CPU OLP for exposing the board 1 3 4 5 2 ...

Page 415: ...Refer to Figure 3 9 Figure 3 9 Electronics box with power board Terminal blocks Plastic cover Electronics box Power board 3 Remove the connectors at a X3 red brown b X7 pink gray c X1 main connector d X2 red brown white Refer to Figure 3 10 Note the wire colors for proper replacement 2 4 3 1 ...

Page 416: ... connector 4 Using a small flathead screwdriver remove the high voltage connectors from the terminal blocks Refer to Figure 3 10 Note the wire labeling for proper replacement 5 Using a phillips screwdriver remove the four 4 mounting screws one at each corner Refer to Figure 3 10 Remove the board Replace 1 Reverse the steps in the removal procedure above 5 6 7 1 2 3 4 ...

Page 417: ...ain in the hose connections Wear rubber gloves and have rags ready for spill age before proceeding to the next step 4 Using a flathead screwdriver loosen the hose clamps securing the two 2 hoses to the pump Refer to Figure 3 11 Remove both hoses Figure 3 11 The circulation pump Hose clamps Circulation pump Power lines electrical connection Mounting plate 5 Follow the black white and green power wi...

Page 418: ...enishment container and drain any excess chemistry in the hose 4 Disconnect the hoses at the pump Refer to Figure 3 12 and Figure 3 13 5 Remove the J hook from the side of the tank 6 Drain off the excess chemistry in the hose 7 Remove the hose from the pump 8 Follow the red white and green yellow power wires electrical connec tion to the terminal block and disconnect NOTE Note the wire positioning...

Page 419: ...ervice Manual 3 16 Removal and Replacement Figure 3 12 The fixer pump Fixer replenishment pump Electrical connection Mounting block Figure 3 13 The Developer Pump Developer pump Power wires Mounting block 1 2 3 1 2 3 ...

Page 420: ... 4 Follow the red white green yellow power wires electrical connection to the terminal block and disconnect Refer to Figure 3 14 Note the wire positioning for proper replacement 5 Loosen the PVC nut on the outside of the tank Refer to Figure 3 14 6 Slide the heating element out Refer to Figure 3 14 Figure 3 14 The heating element assembly Heating element assembly Heating element O ring PVC compres...

Page 421: ... and 1 in the removal procedure above 3 10 Wet Section Temperature Sensor The following describes how to remove and replace the temperature sensor Tools Required Adjustable open end wrench Remove 1 Turn off and unplug the OLP 2 Remove the top and side covers 3 Drain the tank 4 Using an open end wrench loosen the PVC nut Refer to Figure 3 15 5 Pull the sensor out Refer to Figure 3 15 Figure 3 15 He...

Page 422: ...d the tip of the sensor does not exceed 1 Refer to Figure 3 15 3 11 Dryer Section Temperature Sensor 1 Turn off and unplug the OLP 2 Remove the top covers 3 Remove the top back panel 4 Pull the electronics box straight out on its rollers see Figure 3 2 5 Using a socket wrench loosen the PVC nut 6 Pull the sensor out Refer to Figure 3 16 Figure 3 16 Dryer temperature sensor 7 Disconnect the connect...

Page 423: ...eater element Tools Required Tie cutters phillips screwdriver Remove 1 Turn off and unplug the OLP 2 Remove the top covers and left side panel 3 Cut the tie wrap holding the wires to the top right part of the front plate Using a phillips screwdriver remove the screw in the tie wrap holder Refer to Figure 3 17 4 Remove the screw and ground wire in the upper left part of the front plate Refer to Fig...

Page 424: ...Section IV On line Processor Removal and Replacement 3 21 Figure 3 17 Dryer heater element front plate Tie wrap mounting screw fixture Dryer element mounting screws Grounding wire 1 2 3 2 ...

Page 425: ... bolts Refer to Figure 3 18 8 From the front remove the two 2 element mounting screws Refer to Figure 3 18 9 Using a small flathead screwdriver remove the three 3 corresponding wires from the terminal block at the front of the plate Refer to Figure 3 17 CAUTION Note the wire numbering for proper replacement Replace 1 Reverse the order of the removal procedures above being careful to seat the wires...

Page 426: ...r half of the dryer section 4 Remove the heating elements See the removal procedure in Section 3 12 Dryer Blower Motor Assembly above 5 Remove the two 2 screws at the top of the dryer blower unit Refer to Figure 3 19 6 Cut the tie wraps around the sensor on the frame Cut the tie wrap holding the wires to the left side of the dryer blower housing Refer to Figure 3 19 and Figure 3 20 7 Using a phill...

Page 427: ... Service Manual 3 24 Removal and Replacement Figure 3 19 Dryer blower Sensor Top screws Dryer blower unit Dryer heating elements Left side screws electrical connections Terminal block Right side screws 3 2 1 4 6 7 5 ...

Page 428: ...2 d 4 green yellow ground wire Refer to Figure 3 20 CAUTION Note the numbering of the wires for proper replacement Remove the two 2 screws in the terminal block Refer to Figure 3 20 9 Remove the two 2 blower mount screws and pull the housing out Figure 3 20 Dryer blower assembly Blower dryer assembly Terminal block Blower mount screws 1 3 2 4 2 1 3 ...

Page 429: ...Belt The following describes how to remove and replace the entry rack drive belt Tools Required Tie cutters phillips screwdriver 10mm wrench Remove 1 Turn off and unplug the OLP 2 Remove the top covers 3 Remove the side covers 4 Remove the bolts securing the bearing blocks Refer to Figure 3 21 5 Remove the bearing blocks and drive shaft 6 Remove the drive belt Figure 3 21 Entry rack drive belt ass...

Page 430: ...the belt 3 13 2 Drive Shaft 1 Remove the entry rack drive belt See Section 3 13 1 Drive Belt above 2 Remove the allen set screw from the belt wheel 3 Remove all three racks 4 Loosen the three drive motor mounting bolts to loosen the belt Slide the belt from the idler and remove the belt from the drive shaft Refer to Figure 3 22 Figure 3 22 Bearing bracket and drive gear Bearing bracket front Beari...

Page 431: ...oks two at the center one at the rear Refer to Figure 3 23 and Figure 3 24 7 Using a 10mm wrench remove the bolts from the three 3 bearing brack ets located at the front center and rear Lift the drive shaft back and out Refer to Figure 3 22 Figure 3 23 and Figure 3 24 Figure 3 23 Bearing bracket and J hooks Bearing bracket center Two J hooks center 1 2 ...

Page 432: ...ts 2 Replace the racks 3 Raise the drive at the back and front until the worm gears and drive gears are properly meshed 4 Check that the fix worm gear is not deflecting the shaft Adjust as required 5 Tighten all three bearing bracket bolts CAUTION Do not over tighten bolts They are easily stripped of their threads 6 Reverse Steps 1 through 6 7 Power on the machine to check the drive operation 1 2 ...

Page 433: ...out the following Servicing Checking Sensor Operation Checking Operation of the LCB Checking the Battery Setting the Jumpers Calibrating Jumper Settings LUTH Motor Control Board 24V DC P N 5202Y000100 LUTH Motor Control Board 180V DC P N 5203Y4000200 Replenishment Pumps Calibration Troubleshooting The Service Program Service Program Codes How to Use the Repair Method Tables ...

Page 434: ...pulse of the opti cal interrupter Reading should range from 12 V detector gap open to 0 V detector gap closed 4 2 1 2 Film Sensor 1 Check the output Connect the DVM across the appropriate channel to be checked For SENSOR 4 for example measure the voltage between X501 15 and X501 2 A non activated sensor should read 0 V and an activated sensor should read 5 V 4 2 1 3 Temperature Sensor Checking the...

Page 435: ...55 F 12 8 C 605 9 ohm 60 F 15 6 C 615 5 ohm NOTE If temperatures in the bath are incorrect no adjustment is possible The only corrective action available is to replace the defective temperature sensor 4 2 2 Checking Operation of the LCB WARNING All AC power must be off prior to removing the X400 plug 1 Check the power supply circuits a Disconnect the X400 plug Agfa Terminal Board ATB i Measure the...

Page 436: ...ue is 5 VDC ii Reconnect the X500 plug 4 2 3 Checking the Battery 1 Remove the EMC shield of the LCB before checking the battery 2 Connect a DVM across the battery terminals The reading should be 3 0 V If the voltage is lower than 2 5 V the battery should be replaced Note that the normal lifetime of the battery is approxi mately 10 years WARNING Voltage remains in the system even after you turn of...

Page 437: ...ransmitter passive or active S402 S403 Open Open Sink Source current loop receiver passive or active S1 Open Triac Q5 controlled from X1 pin 7 Closed Triac Q5 and Q6 controlled from X1 pin 7 or X1 pin 12 S2 Open Triac Q4 controlled from X7 pin 2 Closed Triac Q4 and Q5 controlled from X1 pin 7 S3 Open Disconnect common of coils from 12V Closed Connect common of coils to 12V S4 Open Disconnect commo...

Page 438: ...Figure 4 1 Newer models use Icons Figure 4 2 Refer to these figures when entering key codes from the Control Panel Both Alphabetical and Icon representation will be given in the procedures Figure 4 1 Old Control Panel with alphabetical key pad J3 A Trigger circuit for Q5 powered from return line N4 B Trigger circuit for Q5 powered from return line N3 85 FILM INPUT LEFT DEV TEMP INCOR LOW LEVEL REP...

Page 439: ...202Y000100 The LMB 24V performs the following functions Amplifies the motor preset value to the corresponding voltage for driving the main motor Receiving and converting R pulse preset values optical link Receiving and converting tacho feedback pulses NOTE The following procedure is for OLPs with serial 3613DD300659 and above See Section 4 3 2 for calibrat ing the 180V LMB The following procedure ...

Page 440: ...meter P102 N Min on the LUTH motor board is not used with infrared pulse transmission To Calibrate the LMB 1 Turn off the processor from the control panel 2 With the control panel off enter the service program by pressing the fol lowing keys in sequence AUTO DRYER SAVER TIME The display should read Service Code ___ 3 Enter code 112 by pressing the following keys in sequence DEV DEV FIX Note DEV 1 ...

Page 441: ...ake a functional checkout NOTE Remember to reprogram preset values in the control panel The motor overload message in the display only visual in normal mode not in service mode appears in this EPROM version as Disconnect Mains Motor Off The following table shows jumper settings for current limiter cut out levels Connections X1 1 2 4 input optical interruptor X2 not used X3 1 2 tacho feedback conne...

Page 442: ...uit Factory adjusted and sealed do not adjust Figure 4 3 LUTH Motor Board LMB To secondary transformer 6 5 Not used To motor Not used Not used Motor Pin 1 M Pin 2 M top signal safety switch Tacho feedback to CPU Optical interrupter Do not change Optical link with CPU board R219 R203 N Min N Max 24VAC M M X102 X2 X4 X4 X3 X1 Fuse 0 5A 5A Current Select P102 I offset Motor Board LMB 02 CPU Board ...

Page 443: ...nel cable is taped to the top of the electronics box to make the procedure easier To Reposition the Control Panel 1 Disconnect the mains i e remove all power to the processor 2 Slide the control panel up and remove 3 Disconnect the control panel cable and take it to the back of the processor 4 Connect the control panel to the X400 with the remote cable WARNING The PCB has high voltage terminals Us...

Page 444: ...nt hose You may have to repeat this several times to clear all the air bubbles c Empty the beaker d Press the manual replenishment key and check the amount of replen ishment released Repeat several times minimum of three pulses e Measure the total amount of replenishment released and divide by the number of times you pressed the replenishment key to obtain an aver age value The correct amount shou...

Page 445: ...gram 322 Press WAT FIX FIX Note DEV 1 FIX 2 WAT 3 Repeat Step 2d from this procedure NOTE After a percent change has been made check the output by entering program 311 for developer or 312 for fix Pressing the 85 key releases one pulse that should equal 100 ml If it does not repeat step 2d NOTE The adjustment range is 0 200 If you reach a value of 200 and are not getting 100 ml per pulse it may be...

Page 446: ... following keys in the sequence shown AUTO DRYER SAVER TIME The display should read Service Code ___ The service codes are represented by a three digit number The keys DEV FIX and WAT can be used for choosing this three digit number NOTE DEV 1 FIX 2 WAT 3 To choose for instance code 132 press DEV WAT FIX The display should read Service Code 132 This is not the case when a service code is chosen wh...

Page 447: ...ess 15 to increase percentage Press 85 to decrease percentage NOTE The service program allows more than one test to run at a time The LED displays only the last code entered WARNING PK7 is always activated with code 232 233 WARNING The service program does not automatically invoke safety measures Be sure to take normal safety precautions when using the program WARNING Never empty the tanks when wo...

Page 448: ... On Off 232 Dryer heat 1 fan Q 4 K 7 On Off 50 key to switchoff K7 233 Dryer heat 2 fan Q 6 K 7 On Off 50 key to switch off K7 311 Dev repl Pump pulses 10 pulses 1 pulse 100ml 312 Fixer repl Pump pulses 10 pulses 1pulse 100ml 313 321 Dev repl pump adjust K 8 adj 0 200 322 Fix repl pump adjust K 9 adj 0 200 323 Lamp Color 331 Warning signals Dev temp incorrect Red Blinking Off Low level Red Blinkin...

Page 449: ... below and note the code number 2 Find the same problem code number in Table 4 3 below and make a note of the numbers listed to the right These refer to the repair steps in Table 4 4 below 3 Follow the repair steps in Table 4 4 in the sequence indicated until the problem is fixed WARNING When the ON OFF switch on the Rapiline OLP is off the display is switched off but there is still voltage in the...

Page 450: ...ven though setting has not been changed 4 0 Dryer Temperature 4 1 Temperature of exit air too high compared to preset 4 2 Temperature of exit air too low compared to preset 4 3 Dryer fan does not stop when film runs out 4 4 Dryer fan does not start when the processor is in operation mode 4 5 Temperature fluctuates even though setting has not been changed 5 0 Replenishment 5 1 Replenishment pump re...

Page 451: ... level LED does not light even though level is low 10 3 Main motor dryer fan etc start even though low level appears 11 0 Replenish Empty 11 1 Replenishment empty LED is flashing even though replenisher contain ers are not empty 11 2 Replenishment empty LED does not light even though replenisher con tainers are empty 12 0 Jog Mode 12 1 Jog mode does not activate main motor and circulator pumps wit...

Page 452: ...05 07 06 4 1 39 40 41 08 21 48 4 2 14 39 40 41 47 04 05 15 4 3 12 10 11 23 4 4 39 14 09 45 24 25 4 5 08 04 05 07 06 5 1 42 43 13 53 5 2 42 43 53 54 5 3 49 50 54 5 4 65 49 50 54 6 1 30 26 66 67 18 17 6 2 30 16 18 6 3 19 6 4 55 67 6 5 56 67 7 1 32 22 20 7 2 32 24 7 3 32 57 58 8 1 31 20 8 2 31 24 9 1 12 27 59 28 59 9 2 30 26 24 67 10 1 44 07 51 10 2 44 07 61 06 10 3 44 07 61 06 11 1 44 53 52 07 11 2 ...

Page 453: ...n 11 Align optical interrupter properly 12 Input sensor electrical or mechanical defect Activated signal constantly transmit ted Verify with service code 332 13 Diode D1 or D2 on LPB board defective 14 Check main fuses and replace any that are defective 15 Heating wire inside heating element is broken 16 Check voltage between terminals 8 and 9 common It should be negative If it is not check tacho ...

Page 454: ... of electronic system with service code 331 45 Blower capacitor defective Replace 46 Verify operation of electronic system with service code 333 47 Built in thermo fuse in heating element is open 48 Incorrect trigger signal to power triac Replace trigger board 49 Time not adjusted on ATB Insert correct time 50 Clock not working due to battery failure Check readout over a period of time Check batte...

Page 455: ... in proper optical sight with infrared transmitter on LCB Align the optical components 68 In the SW all inputs have an attached byte which is coded with a letter for actual use T Temperature input D Digital input L Level input N Not used If the SW detects a signal that does not correspond to the table above a 2001H error is displayed The error is caused by poor or defective Random Access Memory RA...

Page 456: ...age Motors Sensors Tail Punch Sensors 10 11 12 13 14 5 6 7 8 9 10 11 12 13 2 3 14 15 16 17 18 Home Sensor Purchase Sensor Processor Sensor 1 2 3 Buffer Imagesetter OLP Buffer Imagesetter Purchase Sensors Cover Interlocks 3 Tank Level Sensors Output Sensor Waste Not In Position Sensor Waste Full Sensors Replenishment Empty Sensors 1 2 3 4 5 6 7 6 7 3 5 2 Thumb Nut Sensor Shuttle Cassette Mode Senso...

Page 457: ...nt of time Action Check processor for possible media jam Check that the media keeps the exit sensor active when entering the receiving basket Lower the sensor mounting bracket or raise the lower platen as needed Motor Overload Or Disconnect Mains Motor OFF Meaning The processor has detected an error in the transport drive system Action Inspect the processor for possible media jam damaged gears or ...

Page 458: ...LP Specifications This section includes the following OLP specifications Physical Electrical Operational Physical Specifications Length 66 167 64 cm excluding receiver tray 98 248 92 cm including receiver tray roll mat 120 304 80 cm including receiver tray sheet mat Width 61 154 94 cm Height 54 137 16 cm with stand Net Weight 937 lbs 425 02 kg Operating Weight 1136 lbs 515 28 kg ...

Page 459: ...ons Water connection 3 4 BSP 0 3 10 bar max temp 110 43 C Drain 5 3 US Gal 3 x Ø25 mm 3 x 20 L min Water consumption 0 5 US Gal 0 2 L min Tank capacity Developer 8 US Gal 30 3L Fixer 8 US Gal 30 3L Water 8 US Gal 30 3L Temperature range Developer 74 110 F 23 43 C Fixer 74 110 F 23 43 C Temperature settings dryer 86 140 F 30 60 C Material width Max 37 4 95 cm Min 4 10 16 cm ...

Page 460: ... 41 91 cm Fixer 16 5 41 91 cm Wash 16 5 41 91 cm Dryer 19 48 26 cm Developing time range 15 60 sec Speed range 66 16 5 Dry to dry time 83 sec at 20 sec dev time Developer repl rate 50 500cc m2 Fixer repl rate 50 500cc m2 Max dryer blower capacity 21894 Ft3 620 m3 hour Max anti cond capacity 1695 Ft3 48 m3 hour ...

Page 461: ...B 1 Appendix B Spare Parts On Line Processor OLP The following lists and illustrates spare parts for the 36 44 P and OLP ...

Page 462: ...Avantra 36 44 Service Manual B 2 Spare Parts Avantra 36 44 OLP Parts ...

Page 463: ...Side plate left upper front LU 3621E290840 Side plate left lower front LU 3621E290940 Side plate left rear lower 7 LU 3621E291040 Side plate rear lower LU 3601E290140 Side plate rear upper 8 LU 3621E290244 Side plate right upper LU 3621E291340 Side plate right upper front LU 3621E290540 Side plate front right lower LU 3621E290640 Side plate middle right lower LU 3621E290740 Side plate rear right l...

Page 464: ...Avantra 36 44 Service Manual B 4 Spare Parts Avantra 36 44 OLP Parts ...

Page 465: ... right middle lower LU 3611E290740 Side plate right rear lower 4 LU 3611E290144 Side plate left upper LU 3611E290840 Side plate front left lower LU 3611E290940 Side plate rear left lower 5 LU 3601E290715 Film basket comp 6 LU 3601E290140 Side plate rear upper LU 3611E291040 Side plate rear lower 7 LU 3611E290400 Front plate 8 LU 2601Y010201 Wiring harness output sensor 9 LU 1451X000100 Jam sensor ...

Page 466: ...Avantra 36 44 Service Manual B 6 Spare Parts Avantra 36 44 OLP Cassette Parts ...

Page 467: ...621E300742 Feed table upper 3 LU 3621E300602 Feed table lower 4 LU 3621E301134 Stop bar 5 LU 3621E300834 Bottom plate for cassette 6 LU 6221X000203 Gas damper for cassette cover 7 LU 6221X000102 Gas damper for feed table 8 LU 1351Z060401 Slide bearing Ø6 Ø4 x 4 9 LU 1201Z201505 Gear wheel 10 LU 3621E300142 Cassette bottom ...

Page 468: ...Avantra 36 44 Service Manual B 8 Spare Parts Avantra 36 44 OLP Feed Rack Parts ...

Page 469: ...25 0 15 35 8 LU 1282Z161501 Gear M 1 5 Z 16 Ø10H7 9 LU 3611E710100 Guide 91mm FB 10 LU 3611E710200 Curved guide FB 11 LU 3611E710300 Guide 132mm FB 12 LU 3611E710400 Guide 135mm FB 13 LU 2131Z000103 Spring for guide 14 LU 1361Z004701 Bearing block front 15 LU 1361Z004601 Bearing block rear 16 LU 1351Z000101 Bearing reamed to 10 2mm 17 LU 1301Z000805 Drive shaft 18 LU 1331Z000104 Bushing Ø6 Ø10 x 1...

Page 470: ...Avantra 36 44 Service Manual B 10 Spare Parts Avantra 36 44 OLP Tank Parts ...

Page 471: ...ix tank 8 LU 2201Y000201 Heater element 1000 500 W 230 V dev fix tank 9 LU 3230Z000401 Union nut Ø16 3 for heater element 10 LU 8181X000700 O ring 15 88 x 2 62 for heater element 11 LU 2101Y000301 Temperature sensor PT 500 dev fix tank 12 LU 8181X000200 O ring 7 3 x 2 4 nitril for PT 500 13 LU 3230Z000301 Union nut Ø8 1 for PT 500 14 LU 3031Z001301 Lid for drain red 15 LU 3032Z001301 Lid for drain...

Page 472: ...Avantra 36 44 Service Manual B 12 Spare Parts Avantra 36 44 OLP Right Side View Parts ...

Page 473: ...belt pulley T5 21 20 without flange 11 LU 1241Z000102 Tension roller 12 LU 1252Z270501 Drive belt pulley T5 21 27 13 LU 1501X000600 Transformer 14 LU 0104X000500 Motor 24 V 15 LU 1461X000200 Opto interruptor 16 LU 1462X000200 Slotted disc 60 holes 17 LU 0201X000301 Circulation pump for dev fix 18 LU 3230Z002801 Pipe for repl Ø10 Ø7 19 LU 7341X252001 Ball valve 1 V311250 Ø25 20 LU 7342X121221 Valve...

Page 474: ...Avantra 36 44 Service Manual B 14 Spare Parts Avantra 36 44 OLP Control Panel Parts ...

Page 475: ...10Y013100 Control panel P version Keyboard LU 2621X001700 P version LU 6205Y010200 Board control panel LU 6205Y010000 EPROM LU 0507Y013100 Control panel OLP version Keyboard LU 2621X001600 OLP version LU 6205Y010300 Board control panel LU 6205Y010000 EPROM LU 2631Y001201 Internal keyboard cable ...

Page 476: ...Avantra 36 44 Service Manual B 16 Spare Parts Avantra 36 44 OLP Rack Spare Parts ...

Page 477: ...ed guide 39mm 15 LU 2019Z001401 Curved guide 44mm 16 LU 2019Z001501 Curved guide 76mm 17 LU 2020Z000101 Curved guide 84mm 18 LU 3601E220100 Side plate right fixer 19 LU 3601E220200 Side plate left fixer 20 LU 1351Z000103 Bearing upper Ø10 5 21 LU 1351Z000101 Bearing lower Ø10 2 22 LU 1331Z001001 Bushing 23 LU 1331Z000101 Bushing for idler 24 LU 3601E210403 Crossover for dev fix fix wash 25 LU 6292...

Page 478: ...Avantra 36 44 Service Manual B 18 Spare Parts Avantra 36 44 OLP Dryer Spare Parts 18 ...

Page 479: ...LU 1450Z041404 PUR teflon roller Ø25 15 35 7 LU 1351Z000601 Thrust bearing square 8 LU 1282Z161501 Gear M 1 5 Z 16 Ø10H7 9 LU 1221Z011503 Worm for drive shaft dryer 10 LU 1351Z201007 Thrust bearing 11 LU 1361Z004801 Bearing block 12 LU 6321X101510 Bearing bronze with collar 13 LU 1301Z000207 Drive shaft dryer 14 LU 3601E240501 Triple guide lower comp 15 LU 3601E240601 Triple guide upper comp 16 LU...

Page 480: ...Avantra 36 44 Service Manual B 20 Spare Parts Electronics upper Spare Parts ...

Page 481: ...ll 3 Volt 5 LU 6301Y840000 EPROM 36F44V02R02 P version LU 6305Y010000 EPROM 36A44V02R03 OLP version 6 LU 6301Y000501 LUTH computer board LCB 01 with anti loop 7 LU 2304Y000301 Fan 12V 8 LU 4121Z000501 Bracket for plugs 9 LU 4121Z000401 Shield for electronics 10 LU 4101Z000301 Upper part electronics 11 LU 2601Y004201 Fuse holder 12 LU 2621Y007003 Interface cable OLP version only 13 LU 5305Y000101 L...

Page 482: ...Avantra 36 44 Service Manual B 22 Spare Parts Electronics lower Spare Parts ...

Page 483: ...trip 5 circuit 5 LU 4121Z000201 Protective plastic shield NOT SHOWN 6 LU 2401X000100 Fuse holder complete 7 LU 3848 Power triac 25 A 8 LU 1501X000300 Transformer 9 LU 2121X000400 Motor capacitor 10 LU 3847 Trigger Board 11 LU 2501Y003801 Molex 2 wire 12 LU 4101Z000401 Lower part electronics box 13 LU 2411X020000 Fuse 2A 6 x 32 LU 2411X100000 Fuse 10A 6 x 32mm LU 2411X063000 Fuse 6 3A 6 x 32mm LU 2...

Page 484: ...C 1 Appendix C Wiring Diagrams ...

Page 485: ...r Dimensions 1 2 Buffer Exit Platen 1 22 Buffer Leveling Feet 1 23 Buffer to OLP Alignment 1 23 C Calculation Timed Replenishment 2 10 Calibrate the LMB 4 8 Calibrate the Replenishment Pumps 4 12 Calibrating LUTH motor control board LMB 180V 4 11 Calibration LUTH Motor Control Board LMB 4 7 Calibration Replenishment Pumps 4 12 Checking Operation of the LCB 4 3 Checking Temperatures 4 3 Checking th...

Page 486: ...Electrical Connections on line processor 1 17 Electrical Supply 1 17 on line processor 1 17 Electrical Imagesetter 1 3 Electrical OLP 1 2 A 2 Electronics 2 3 on line processor Luth computer board LCB 2 3 Electronics Box 3 4 3 5 3 6 3 12 Engine Crate 1 5 1 8 Entrance Rack Assembly 1 20 Entry Rack Assembly 3 26 Error Messages 4 25 Evaporation 2 9 Evaporation Cover 1 6 Evaporation Covers Location 1 3...

Page 487: ...Dollies 1 12 Locations of Switches And Sensors 4 24 Locations of Wiring Connections 1 18 Low Level Mode 2 3 Lower Front Covers for Entrance Rack 1 6 Lower Platen of Entry Rack 1 21 Lower Rear Panel 1 20 1 24 LPB 2 5 2 6 LRB 3 10 LRB Board 3 11 LUTH Computer Board functions 2 3 Luth Computer Board 2 3 LUTH Motor Board 2 8 description of inputs and outputs 2 8 functions 2 8 LUTH Motor Control Board ...

Page 488: ... Crate 1 5 Operate Mode 2 2 Operation on 208 240V N 50 60HZ 1 18 1 19 Operational Specifications OLP A 2 Optical Interrupter 2 8 Optocoupler pcb Diode 2 7 Output digital Output 2 5 Overflow Supports 1 30 Overflow Tubes 1 30 P Panels 1 24 left side bottom 1 24 Panels and Covers Attaching 1 24 Parts Crate 1 5 Parts Inventory OLP 1 6 Photologic IC 2 8 Physical Specifications OLP A 1 Placing Chemistry...

Page 489: ...ture 2 8 Sensors and Switches diagram 4 24 Service Program 4 14 Service Program Codes 4 16 Servicing on line processor 4 2 Setting the Jumpers LCB settings 4 5 LPB settings 4 5 Shipping Crates OLP 1 5 Side Panels front 1 24 rear 1 24 Solenoid Valve 1 16 Space Requirements on line processor 1 2 Specifications A 1 on line processor A 1 physical OLP A 1 Specifications On line Processor OLP A 1 Stabil...

Page 490: ... the Repair Method Tables 4 17 V Variations in AC Supply Voltage 1 18 W Wash 1 27 Wash Rack 1 6 Wash Recirculator 1 16 Water consumption 1 16 Water Connection 1 16 Water Requirements OLP 1 3 Water Supply 1 15 Water Supply Drainage 1 16 Weight OLP 1 2 Wet Section Temperature Sensor 3 18 Wiring Configurations 208 240V single phase 50 60Hz 1 18 208 240V three phase 50 60Hz 1 18 230 240V N 50 60Hz 1 1...

Page 491: ...Section V Crane ...

Page 492: ...1 Introduction This chapter explains how to unpack and install the Avantra 36 44 crane which attaches to the on line processor OLP This chapter covers Unpacking the Crane Crane Installation Procedures The Mounting Plate and Boom Mounting the Head ...

Page 493: ...ers Steps 1 Move the packing box to the imagesetter site and place it on the right hand side of the OLP 2 Cut the ties around the box Lift off the top and remove the packing 3 Lay out and check the contents against the items shown in Figure 1 1 Figure 1 1 Crane inventory Boom arm mast assembly Cassette cable Capture bar Head rack cassette crane 1 2 4 3 ...

Page 494: ... side of the OLP Refer to Figure 1 2 NOTE Later OLP models should have the mounting plate assem bly already in place 3 If the Mounting bracket is not in place use a 17mm socket wrench to attach it to the frame Use the four bolts washers and lock washers sup plied Refer to Figure 1 2 NOTE A 17mm socket is supplied to aid in securing the mounting bracket Figure 1 2 Crane mounting plate assembly Four...

Page 495: ...r fit into mount Mount NOTE Later OLP models should not require the following proce dure 5 Replace the top side panel to the OLP and verify that the panel cut out for the crane has an acceptable fit Refer to Figure 1 2 and Figure 1 3 If the fit is not good remove the adapter and mounting plate Re install the plate with washers added between the mounting plate and the frame This will improve the al...

Page 496: ...er Refer to Figure 1 4 7 Lower the boom into position until the boom fits snugly into the adapter mount Refer to Figure 1 4 8 With the boom adapter in place in the mount connect the boom power cable to the matching plug at the OLP Refer to Figure 1 4 Figure 1 4 Crane power cable connections Mount Mounting bracket Electrical cable with connector 4 5 3 ...

Page 497: ...cks the boom in place once the set screws have been tightened against the adapter Make sure the locking pin is facing straight out as shown before tightening the set screws Note that the adapter has recesses for the set screws Figure 1 5 Mounting the boom into the adapter mount Spring loaded locking pin Boom Adapter Four mounting plate bolts with washers Mounting bracket Two allen set screws in mo...

Page 498: ...lathead screwdriver remove the end stop mounted at the tip of the boom arm Refer to Figure 1 6 Figure 1 6 The boom with side rails and end stop Boom rail End stop 2 Remove the plastic end cover from the head at the rear the end farthest away from the cable exit Note the power connector behind this cover 1 2 ...

Page 499: ...e boom travel areas Refer to Figure 1 7 The plug has a tag on the end labeled Remove Plastic Plug CAUTION Once this plug is removed the head should not be turned over on its sides for any period longer than a few minutes Figure 1 7 The gearbox vent plug Head rack cassette crane Plastic plug 1 2 ...

Page 500: ...m arm power connector end first Push the first two guiding rollers over the boom rails see Figure 1 6 and roll approximately halfway onto the boom Refer to Figure 1 8 Figure 1 8 Mounting the head Head Rear mounting bracket Roller Power cable connector 1 4 2 3 ...

Page 501: ...f the boom arm past the first set of guide roller mounting blocks on the head Refer to Figure 1 9 Figure 1 9 Routing the power cable Roller Rear mounting bracket Power cable connector Head Crane boom 6 Loop the cable around the guide roller mounting block on the left side as viewed from above Refer to Figure 1 9 2 1 4 5 3 ...

Page 502: ... Move the head to its limit against the end stop at the boom tip Pull out any slack left in the cable and secure to the wire tie securing block at the end of the head 11 Roll the head back and forth several times while observing the cable rout ing to ensure it is properly placed 12 Switch on the OLP power 13 Switch on the power at the crane control panel and check the operation of the unit 14 Oper...

Page 503: ...ion This chapter explains how to remove and replace components within the Avantra 36 44 crane which attaches to the on line processor OLP This chapter covers Crane Removal Replacement Procedures Crane On Off Switch Crane Motor Crane Slack Safety Switch Crane Cable ...

Page 504: ...n the OLP and disconnect its power plug 2 Remove the top covers and using a phillips head screwdriver remove the four 4 screws on the top and three 3 screws on the bottom of the right side panel Refer to Figure 2 1 and 2 2 Lift and remove the side panel Figure 2 1 OLP cover and panel identification and location Forward top cover Middle top cover Rear top cover Top side panel 4 3 2 1 ...

Page 505: ...Section V Crane Removal and Replacement 2 3 Figure 2 2 Screw locations OLP top side panel Location 4 hex screws top of side panel Location 3 hex screws bottom of side panel 2 1 ...

Page 506: ...ra 36 44 Service Manual 2 4 Removal and Replacement 3 Disconnect the power cable coming from the crane assembly to the plug inside the OLP Figure 1 3 Figure 2 3 The crane power cable Power cable connector 8 ...

Page 507: ... Replacement 2 5 4 Using a phillips head screwdriver remove the two 2 screws attaching the switch plate to the crane arm Figure 1 4 Figure 2 4 Screw location on switch plate Up down switch On off switch Phillips screws O I 1 2 3 ...

Page 508: ... the switch wiring for proper replacement Figure 1 5 Remove the wires Figure 2 5 Crane switch wire color and location Light blue Thin black Thin brown Dark blue light blue Thick white Thick brown thin brown Thick black Thin brown Replace 1 Reverse the removal procedures above 7 8 4 5 6 3 2 1 ...

Page 509: ... Using a phillips head screwdriver remove the four 4 screws on the front and back cover of the head 3 Disconnect the power cable at the end of the head 4 Using a flat head screwdriver remove the three 3 screws in the end stop at the front of the boom Figure 1 6 5 Carefully roll the head off the boom rails Figure 1 6 Lay the head down on a flat surface with the top open end up Figure 2 6 Boom rails...

Page 510: ... removal tool remove the pins in the plug WARNING Make note of the location of the wires for replacement purposes 10 Push the wire through the hole 11 Flip the motor assembly over and remove the P clamp holding the wire in place 12 Using a 5 32 allen wrench remove the two 2 screws attaching the motor to the plate Replace 1 Replace the 5 32 allens 2 Align the motor coupler with the coupler on the m...

Page 511: ...the end stop at the front of the boom Figure 1 6 4 Carefully roll the head off the crane boom Lay the head down on a flat surface with the top open end up 5 Using a 9 64 hex wrench remove the four 4 hex screws at the top of the head CAUTION While removing the screws support the motor at the cable end 6 Pull the cable and hook up through the hole in the head 7 Spread the sides of the head and slide...

Page 512: ...r cable at each end of the head 4 Using a flat head screwdriver remove the three 3 screws in the end stop at the front of the boom Figure 1 6 5 Carefully roll the head off the boom rails Figure 1 6 Lay the head down on a flat surface with the top open end up 6 Using a 9 64 hex wrench remove the four 4 hex screws at the top of the head This Detaches The Motor Assembly CAUTION While removing the scr...

Page 513: ... and Replacement 2 11 9 On the motor side remove the E clip to detach the cable sheave pin and sheave Figure 1 7 Figure 2 7 E clip Sheave and sheave pin Cable Sheave pin Sheave Drive assembly Drive coupler E clip 3 6 5 1 4 2 ...

Page 514: ...sembly over and remove the four 4 3 16 allen screws that connect the top plate to the cable drum assembly Figure 1 8 Figure 2 8 Top plate Two 5 32 allen screws Cable drum assembly Two 3 16 allen screws long Top plate Two 3 16 allen screws short Motor power cable 1 2 5 4 3 6 ...

Page 515: ...wrench remove the screw from the cable guiding block Figure 1 9 Figure 2 9 Cable drum with guiding bar and block Cable drum Slack safety switch wires Two phillips screws for safety switch Slack safety switch Guiding bar Guiding block One 5 32 hex screw 14 Continue to turn the drive coupler clockwise until the set screw is visible in the drum Figure 1 10 Use a 1 16 allen wrench to loosen the set sc...

Page 516: ... cable end into the cable hole in the Drum Figure 1 10 3 Tighten the set screw Figure 1 10 4 Turn the drive coupler counterclockwise while maintaining tension on the cable Figure 1 7 Wrap the cable at least one and one half times around the drum 5 Re attach the guiding block Figure 1 10 6 Continue to turn the drive coupler until the cable wraps 2 3 times more on the drum Keep checking that there i...

Page 517: ...rriage assembly 067246 004 Up Down rocker switch 067246 005 Circuit breaker On Off switch 067246 006 Cable assembly 067246 011 Cassette chain 067246 016 Carriage cover 067246 017 Cable slack switch w actuator 067246 018 Cable slack switch w o actuator 067246 019 Hoist limit switch ...

Page 518: ...2 11 Cable Crane 2 10 Cable Replacing 2 14 Capture Bar 1 2 Cassette Cable 1 2 Contents Crane Carton 1 2 Control Switches 1 6 Crane adapter 1 6 boom 1 5 installation procedures 1 3 motor 2 7 mount 1 5 mounting bracket 1 3 1 5 1 6 mounting plate 1 3 1 4 on off switch 2 2 power cable 2 4 removal and replacement procedures 2 2 unpacking 1 2 Crane Arm 2 5 Crane Assembly 2 4 Crane Cable 2 10 Crane Carto...

Page 519: ...ounting the Adapter Locking Sleeve 1 6 Mounting the Head 1 7 1 9 O OLP cover and panel identification 2 2 forward top cover 2 2 middle top cover 2 2 side panel 2 3 top side panel 2 2 On off Switch location 2 5 removing and replacing 2 2 On Off Switch Crane 2 2 P Pin Removal Tool 2 8 Placing Head onto Boom Arm 1 9 Plate 1 3 Power Cable 1 10 location 2 4 Power Cable Connections Crane 1 5 Power Cable...

Page 520: ...p Pin 1 6 Switch crane slack safety 2 9 On off 2 5 plate 2 5 screws 2 5 slack safety 2 13 Up down 2 5 wire colors 2 6 wire locations 2 6 wiring 2 6 Switch Block screws 2 9 Switch Plate 2 5 T Top Plate 2 12 Top Side Panel location 2 2 screw locations 2 3 Top Side Panel Removing 1 3 U Unpacking the Crane 1 2 Up down Switch location 2 5 V Verifying Properly Cable Routing 1 11 W Wiring Switch 2 6 ...

Page 521: ...Avantra 36 44 Service Manual I 4 Index ...

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