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Service Manual Mako Series
Service Manual Mako Series
Reference Manual
RETURN
AG11902 Rev. 5
MAKO
Reference Manual
This manual reflects the MAKO as of February, 2000.
copyright ECRM Incorporated 2000
Information on ordering additional copies of this manual may be obtained by writing or calling:
ECRM Order Processing
554 Clark Road
Tewksbury, MA 01876
Phone No. (US) - (978) 851-0207 Fax (US) - (978)-851-7016
Phone No. (UK) - (44) 1923-218255 Fax (UK) (44) 1923-218256
Phone No. (Hong Kong) - 852-2-564-8989 Fax (Hong Kong) 852-2-564-8821
Proprietary Notice
The information contained within this guide is the property of ECRM Incorporated. No transmission, reproduction, transcription, storage in a retrieval system, translation into any language, or other use is permitted in
whole or in part in any form without first obtaining written permission of ECRM Incorporated.
List of Trademarks or Registrations, ECRM is a registered trademark of ECRM Incorporated, PelBox is a registered trademark of ECRM
Incorporated, KnockOut 4550 is a registered trademark of ECRM Incorporated, KnockOut/PRF is a registered trademark of ECRM Incorporated, Marlin is a trademark of ECRM Incorporated.
AG11902 Rev. 5
AG11902 Rev. 5
AG11902 Rev. 5
AG11902 Rev. 5
Locate the Pinch Roller Release Lever in the Accessories Bag (which also contains the power cord).
2.
3.
Locate the slot on the left side of the input cassette compartment. Note the threaded hole in the shaft behind
the slot.
4.
Install the Pinch Roller Release Lever into the threaded hole.
5.
Move the shaft back and forth several times to verify smooth operation.
install
lever
here
1.2 Installation
1.2.1 Site Preparation
The following section explains the procedures required of the customer when planning for installation of the
Recorder. The customer should follow the procedures to help ensure a trouble-free installation.
1.2.1.1
Customer Responsibilities
Providing the exact location of the Recorder with adequate floor space for installation and testing.
2.
3.
AG11902 Rev. 5
1.2.1.2
Environmental Requirements
Floor Requirements
For Recorder: The imagesetter should be placed on a table and in an area appropriate for is specific size
and weight. (Refer to Section 1 - Physical Data for weights and dimensions.)
NOTE: Mako series systems are table top designs. When choosing a table to set the system on, make sure it is
sturdy enough to support the weight of the system.
For Installation and Testing: Add an additional 2' (61cm) on each side of the recorder to allow enough space to
remove the cover for testing.
Traffic: Locate the recorder in a low traffic area to ensure operator comfort, machine safety and cleanliness.
Vibration: The recorder must be located in an area that is free from vibration. Excessive vibration can cause distortion of the output.
Temperature: Refer to section one for operating temperature, relative humidity, and storage temperature.
Heat Dissipation: 1000 BTU/hr maximum.
Ambient Light: Normal room lighting is acceptable. Avoid areas of extreme brightness. Such areas may produce fogging on the output media.
Air Quality: The environment should be as dust free as possible. Dust will impair the optimum operation of the
optics.
System Power: See UTILITY REQUIREMENTS: on page 16, Auto Ranging, for system power specifications.
The Recorder may exhibit problems if subject to static electricity. Therefore the system should not be placed in a carpeted area. Use anti-static mats as necessary.
AG11902 Rev. 5
2.
Set up, clean, and level the system at the location designated by the customer.
3.
Check the system off-line using test patterns 3 and 4 to determine sizing, squareness, focus, and registration.
4.
5.
6.
Conduct on-site training of personnel who will operate or supervise the operation of the Recorder system.
7.
Provide a check list for the customer to ensure proper installation procedures have been followed.
CAUTION:
STARTUP TEMPERATUREIf the imagesetter has been stored in a low temperature environment
it must warmup to at least 62F (17C) before it is powered on. Powering up a cold imagesetter
may damage the temperature sensitive components that it contains.
OPERATING TEMPERATUREThe imagesetter must be used in a normal operating environment
of 62-86F (17-30C). Failure to operate within this temperature range may result in degradation
of output quality.
Protective Earth
This product is protected by a protective Earth terminal. This protective Earth terminal is the third conductor in the
appliance inlet. This product must be installed near a socket outlet (which has a protective Earth conductor) and this
socket outlet must be easily accessible. The reason for this is that the plug on the power cord is intended to serve as
the disconnect device.
Electrical Safety
There are no user serviceable parts inside this product. Refer all repairs to a properly trained service technician.
Power Cord Types
Refer to AG11320 for proper cordset selection for your area.
AG11902 Rev. 5
Mako
Scan Mode:
(x-axis)
Media Transport
(y-axis):
COMPLEMENTARY
MACHINE FEATURES:
Desktop Design
Daylight operation
Automatic media cutting
Automatic end of media warning signal
Adjustable start of line
Host control of resolution and speed
Host control of full exposure range
On line processor interface
High Capacity takeup cassette
Bulk load supply cassette
10
AG11902 Rev. 5
Mako
MEDIA:
Media-Visible Red
Visible sensitive film(polyester base) or paper or *plate material - all 0.004"0.007" thick
Media-Infrared
IR sensitive film (polyester base) or paper or *plate material - all 0.004"- 0.007"
thick.
*0.007 material may be used with an online processor or with a special take-up cassette.
Emulsion type:
Roll designation:
Emulsion in, rolled on 2" heavy duty I.D. core. Break away taped to core, 400ft.
(120mm) long: O.D. - 5.7" max
Width:
Shaft # 1:
460mm (18.11)
450.85mm (17.75)
416.4mm (16.38)
406.4mm (16.00)
400mm (15.75)
390mm (15.35)
369mm (14.52)
355.6mm (14.00)
338mm (13.31)
310mm (12.20)
300mm (11.80)
Input Cassette:
Bulkload
Darkroom loaded (green safety light). Capacity - one (1) roll, for use of media.
400 foot cassette
Output Cassette:
Processing
AG11902 Rev. 5
Shaft # 2:
457mm (17.99)
440mm (17.32)
430mm (16.93)
420mm (16.54)
379.98mm (14.96)
330mm (12.99)
317mm (12.48)
11
Mako
RECORDING PERFORMANCE
Media Size:
Exposure Width:
Image Size
Mako 3600/4600
Overscan
OFF
ON
*18"
18.0
18.15
14"
14.0
14.17
12.2"
12.14
12.23
12"
12.01
12.17
Image Location
ACCURACY:
Resolution
Addressability:
ENGLISH:
2400/1200; 1800; and
1000 lpi
METRIC:
3556 (140 lpmm)
3048/1524 (120/60 lpmm)
2540/1270 (100/50 lpmm)
2032/1016 (80/40 lpmm)
1446 (57 lpmm)
12
AG11902 Rev. 5
Absolute
Dimensional
Accuracy
Repeatability:
Mako 3600/4600
Mako
175.0 lines per second, 10500 lines per minute. (Refer to Table 2 of the Interface Spec).
Mako 3625/4625
267.0 lines per second, 16000 lines per minute.
Mako 3650/4650
350.0 lines/second, 21000 lines per minute.
Mako 3675/4675
533.0 lines per second, 32000 lines per minute.
AG11902 Rev. 5
13
Mako
Video Data Rates
Mako 3625/4625
101.3 MHz @ 3556 dpi
86.9 MHz @ 3048 dpi
72.3 MHz @ 2540 dpi
68.5 Mhz @ 2400 dpi
57.8 MHz @ 2032 dpi
51.3 Mhz @ 1800 dpi
43.5 MHz @ 1524 dpi
41.3 MHz @ 1446 dpi
36.1 MHz @ 1270 dpi
34.2 Mhz @ 1200 dpi
28.9 MHz @ 1016 dpi
28.4 Mhz @ 1000 dpi
14
Mako 3650/4650
119.3 MHz @ 3556 dpi
114.4 MHz @ 3048 dpi
96.0 MHz @ 2540 dpi
90.6 Mhz @ 2400 dpi
76.8 MHz @ 2032 dpi
68.0 Mhz @ 1800 dpi
57.6 MHz @ 1524 dpi
54.6 MHz @ 1446 dpi
48.0 MHz @ 1270 dpi
45.4 Mhz @ 1200 dpi
38.4 MHz @ 1016 dpi
37.8 Mhz @ 1000 dpi
Mako 3675/4675
119.2 MHz @ 3556 dpi
119.0 MHz @ 3048 dpi
118.7 MHz @ 2540 dpi
120.0 Mhz @ 2400 dpi
115.8 MHz @ 2032 dpi
102.6 Mhz @ 1800 dpi
86.9 MHz @ 1524 dpi
82.4 MHz @ 1446 dpi
72.4 MHz @ 1270 dpi
68.4 Mhz @ 1200 dpi
57.9 MHz @ 1016 dpi
57.0 Mhz @ 1000 dpi
AG11902 Rev. 5
Mako
Throughput Speed:
AG11902 Rev. 5
Mako 3600/4600
Mako 3650/4650
Mako 3625/4625
Mako 3675/4675
15
Mako
SCREEN CHARACTERISTICS:
Dot% Range:
5% to 95%.
Dot % Uniformity:
Density
3.5Dmin
OPTICAL DATA:
Light Source:
Visible
Light Source:
Infrared
Spot Size:
ELECTRONIC DATA:
ECRM Interface:
SCSI Interface:
PHYSICAL DATA:
Dimensions:
Weight:
UTILITY REQUIREMENTS:
Power:
HEAT DISSIPATION:
1000 BTU/HR (MAX)
ENVIRONMENTAL CONDITIONS:
Operating:
16
AG11902 Rev. 5
Mako
Storage:
0 to 130F (-18 to 54 C) DELTA temp. not to exceed 25 per hour (14 C per
hour)
Relative humidity NOT over 65% with NO condensation.
SAFETY REGULATIONS:
CSA
TV
FCC
DOC
EMC
AG11902 Rev. 5
17
18
AG11902 Rev. 5
Interlocks
Index (7)
Encoder
Sensors/
Switches
Control
Panel
Film
Drive
Encoder (6)
Capstan Roller
(Advances film or
photographic paper)
Feedback
Detector
Laser Diode
Deflector (3)
(deflects the beam
across the media)
Scan
Lens
Spinner
Motor
Optics
Assy (4)
Encoder
Index (7)
Spinner (5)
Controller
Board
AP27231
Indicates Path of
Laser Beam
PhaseCLK
Notes:
1
2
3
4
Mako = AP24507P3
Mako (visible) 24680/24525
Mako (IR) 24501/24503
All Mako models
Mako 3600/4600 (visible) = AO24707
Mako 3600/4600 (IR) = AO24708
Mako 3625/4625 (AKA Mako 36/46) = AO24707
Mako 3675/4675 (AKA Mako 36/46 with High Speed Option = AO28515
Mako 3650/4650 (visible) = AO24690
Mako 3650/4650 (IR) = AO27202
AG11902 Rev. 5
5
6
7
19
SLOW
START
EXPOSURE
8 BITS
/LASERENB
/BEAMON
/LASERCAL
BIAS
CIRCUIT
EXPOSURE
SERVO
/FINDSOL
LASER DIODE
20
AG11902 Rev. 5
SOL (2)
AMP
EEPROM
CPU
CONTROL
PANEL
INTERFACE
EPROM
RAM
FILM
DRIVE
SPINNER (1)
DRIVER
ADDRESS
DATA
STATUS
SCSI/
PELBOX
INTERFACE
ADDRESS
DECODING
LINE
BUFFER
CONTROL
REGISTERS
CUTTER
DRIVER
SYSTEM
TIMING
NOTES:
LASER DRIVER
BOARD
AG11902 Rev. 5
21
S1A
*S1A
Power
Supply
S1B
+24 Volts
Cutter
Motor
Controller
Board
*S3B
S2
+24 Volts
Laser
Driver
Laser
CUTTER
CUTENABLE
/DOOR OPEN
Cutter Motor
Drive Circuit
+24 Volts
Spinner
Controller
Board
Spinner
Motor
Cutter
Motor
Switch
Open
Short
S1A
No Operation (HW)
S1B
S2
S3A
No Operation (HW)
S3B
22
AG11902 Rev. 5
control panel.
S3AMonitors status of top cover panel, interrupts +24 Volts between power supply and Controller Board, removes power to
laser driver board and spinner motor.
S3BMonitors status of top cover panel, hardware prevents cutter motor from being enabled, firmware turns off laser and all
motors except the spinner motor. Exception is that film drive motor is allowed to operate by pressing momentary button on
control panel.
AG11902 Rev. 5
23
24
AG11902 Rev. 5
Introduction
NOTE: These procedures apply to 2.0.6 Firmware and above. Contact Customer Service with any questions on
previously released firmware.
This section contains procedures to remove, replace, adjust or align the major sub assemblies of the Mako systems.
Mako Series systems do not require that you perform any board adjustments or optical alignments. This section provides the following procedures to remove, replace, adjust or align a failed sub assembly in the field.
3.2
CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS
CAUTION:
All procedures must be performed by a qualified service technician and they should always wear a
grounded static wrist strap prior to performing any removal or replacement procedures.Whenever
a service technician performs ANY maintenance or removal and replacement procedures, it is
extremely important to perform the following:
1) Before working inside the system, first connect the laser diode shunt. The shunt location is
shown in Figure 3-1 on page 26. Connect this shunt EVERY time you remove the system cover,
unless the procedure you are performing specifically states otherwise. If you do not connect this
shunt, the laser diode assembly will be damaged.
2.Once the changes are made and all cables are reconnected, the shunt can be removed.
Systems with an AP9993 laser driver board have the shunt attached to the laser diode cable. Systems with an AP24524, AP24501, or AP24680 laser driver board, have a shunt on the laser switch
board (Refer to Figure 3-1 on page 3 - 26). In earlier systems, the shunt was not provided with the
cable. Use shunt FX0030 (provided in the Tooling Kit) if your system does not have the attached shunt.
Install the shunt whenever you are removing and replacing a PC Board.
AG11902 Rev. 5
25
3.3
3.4
Power down the system. Leave the system plugged into the outlet for earth ground.
2.
Wear a wrist grounding strap and attach it to the jack on the side of the recorder.
3.
Remove the systems back cover by loosening the center screw in back. Lift the rear of the cover and slide it
back, then remove it.
4.
Install the laser diode shunt. See Figure 3-1 for shunt locations.The shorting plug location depends on the
type of optics assembly. To install the shunt verify which system you have.
Side Views
Shunt
Shunt
Shunted
Unshunted
Remove
(Unshunted)
Install
(Shunted)
Unshunted
26
AG11902 Rev. 5
2.
Install the back cover by sliding it forward and tightening the center screw in back.
3.
2.
Remove the system back cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.) Although the
gas shock is located in the front of the system, removing the rear cover makes it easier to perform this procedure.
3.
4.
The Gas shock is mounted on two pins that secure it to the imagesetter. One pin is located on the top cover,
and the other pin is located on the imagesetter chassis. To remove the gas shock, use a screw driver as a lever
and remove each end of the shock from the pin that secures it.
5.
Install the new gas shock by pushing each end of the shock onto the appropriate pin on the top cover and on
the chassis. You may need to use a screwdriver as a lever to snap the shock onto each pin.
Top Cover
Gas Shock
Replace the system cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
AG11902 Rev. 5
27
2.
Remove the system back cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
3.
Open the system front cover. The cover sensor is located on the back side of the front cover (Figure 3-3).
4.
The cover sensor is mounted with three screws and is attached to a wire connector. Remove the wire connector and remove the nuts from the three mounting screws to remove the cover sensor.
5.
Install the new cover sensor, tighten the nuts on the three mounting screws, and attach the wire connector to
the new cover sensor.
Wire Connector
Top Cover
Mounting Screws
Figure 3-3 Cover Sensor
6.
28
Replace the system cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
AG11902 Rev. 5
3.5
2.
3.
CAUTION:
a.
b.
c.
d.
e.
Ground cable.
Remove the scan lens mask (if equipped) by removing the two screws and lifting the cover straight up.
The optics assembly is heavy. While removing the optics be very careful to support the assembly,
and then pull it up and out toward you while removing it. Do not let the assembly fall down toward
you while removing it up and out of the system. Ensure that the laser driver board(s) do not hit the
base of the system.
4.
Using a 9/64 allen wrench (T-handle) remove three screws from the optical bed plate. Support the optics
assembly to prevent it from falling, then remove the fourth screw (Figure 3-4).
5.
Screws
Screws
AG11902 Rev. 5
29
1.
3.5.2.1
Removing the Spinner Motor from the Old Assembly
Wear a static wrist-strap and ground it to the system as directed in Section 3.3.
2.
Place the new optics assembly, scan lens down, on a clean, flat surface.
3.
Remove the protective plastic cap from the spinner motor hole on the new optics assembly.
Motor body
Mirror
Alignment scribe*
Figure 3-5 Spinner Motor
NOTE: * There is no scribe mark on 3600, 3625, 4600 or 4625 Makos (AKA Mako 36/46). Use the start of line sensor at the image plane for a left margin reference on these systems.
4.
Cut the tie wrap that holds the spinner motor cables to the optics, and with a 5/32" Allen wrench, remove 3
mounting screws from around the Spinner Motor in the old optics assembly. Support the motor with one
hand to prevent it from falling out. Set the screws and their washers and spacers aside carefully to replace
later.
5.
Carefully remove the Spinner Motor by lifting it straight out, being careful to not let the mirror touch any
part of the chassis.
3.5.2.2
NOTE: Do not touch the Spinner Motor Mirror for any reason.
30
1.
2.
Align the scribe mark on the edge of the Spinner Motor with the scribe mark on the housing.
3.
Install and torque the three mounting screws with their washers and spacers to 15 in/lb.
4.
AG11902 Rev. 5
Begin
AC24657
coax
supplied?
AP24680
Laser Driver
?
Yes
No
No
Yes
Set Laser
Driver J6 A-B
Firmware
V 2.3.5 or
higher
?
Yes
Firmware
V2.3.2 or
Higher?
No
No
Set J8 to
B-C
Yes
AP24507
rev. E or
higher?
Install shim
between pin
and channel on
side it was
taped
No
Remove
AC24657 Coax
Set J8 to
A-B
Install 4 screws
between pin
securing optics
to channel
Install shim
between pin
and channel on
side it was
taped
Connect:
-Ground cable
-Ribbon cable
to laser driver
-Spinner cable
to AP27231
-Spinner cable
to AP24507
Install 4 screws
securing optics
to channel
No
Install cover
Install 4 screws
securing optics
to channel
Install scan
lens mask (if
removed)
Connect:
-Ground cable
-Ribbon cable
to laser driver
-Spinner cable
to AP27231
-Spinner cable
to AP24507
Remove laser
diode shunt
Firmware
V2.3.2 or
Higher?
Set Laser
Driver J6 B-C
Install shim
between pin
and channel on
side it was
taped
Set Laser
Driver J6 A-B
Install scan
lens mask (if
removed)
Yes
Yes
Install scan
lens mask (if
removed)
Connect:
-Ground cable
-Ribbon cable
to laser driver
to laser driver
-Spinner cable
to AP27231
-Spinner cable
to AP24507
-Coax cable to
AP24507 P1
Remove laser
diode shunt
Install cover
and turn on
power
Install cover
and turn on
power
Remove laser
diode shunt
Set front panel
/BEAMON to
RIBBON
CABLE P4
Install cover
AG11902 Rev. 5
31
Remove the system cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
2.
Check the optics to see if an AP24680 laser driver board is installed. Note: AP24680 laser driver boards are
used on visible systems only.
If an AP24680 is installed, proceed with step 3.
If an AP24680 is not installed, proceed with step 6.
NOTE: All Mako systems contain an AP24680 laser driver board and firmware version 2.3.5 or higher.
3.
If the optics has an AP24680 installed, check the version of the firmware installed on the main controller
board.
4.
5.
6.
Check the optics to see if they have been supplied with an AC24657 coax BEAMON cable attached to P5 of
the laser driver PCB. If the optics were not supplied with an AC24657, continue with step 7. If they were
supplied with an AC24657, proceed with step 17.
7.
If the laser driver is not supplied with an AC24657 coax BEAMON cable, set jumper J6 on the laser driver
board to the A-B position. Note: This position is hard-wired on the IR systems.
8.
Install shim (if provided) between the reference pin and the optics channel. The shim is attached to the optics
assembly with cellophane tape and should be installed on the same side of the optics that it is taped (e.g. a
shim taped to the left side of the optics should be installed under the left reference pin). Discard the tape.
Ensure the reference pins are seated securely against the shim or optics channel.
Pin
Pin
Possible
Possible
Shim Location
Shim Location
2 Mounting Screws
2 Mounting Screws
32
Remove the old shims and replace them with the new shims that are shipped with the new optics
assembly. Using the old shims with the new optics assembly could cause a System Error 2. Keep
the old shims with the old optics.
AG11902 Rev. 5
9.
Install the 4 screws (2 on each side) that hold the optics to the channel.
10.
For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2 screws to
secure.
11.
For visible systems, if the scan lens mask was removed from the channel, replace it with the mask provided
in the kit and tighten the two screws to secure it.
Connect the following cables:
a.
Ground cable.
b.
c.
d.
12.
Remove the shunt from the diode on the laser diode board.
13.
Check the firmware version on the AP24507. If the version is lower than 2.3.2, proceed with step 14. If it is
version 2.3.2 or higher, proceed with step 15.
14.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment.)
15.
Replace the systems cover as described in Section 3.4.2 and turn the power on.
16.
Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously. Press the
NEXT key until the /BEAMON PATH? menu is reached. Select RIBBON CABLE P4. Press the NEXT key
and save the settings. Proceed with system warmup and calibration.
17.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment.).
If the optics assembly was supplied with an AC24657 coax BEAMON cable attached to P5 of the laser
driver PCB, check if the AP24507 firmware version is 2.3.2 or higher. If it is not version 2.3.2 or higher, proceed to step 18. If the firmware version is 2.3.2 or higher, proceed with step 26.
18.
If the AP24507 firmware version is lower than 2.3.2, do not use the AC24657 coax BEAMON cable.
Remove the coax cable from P5 of the laser driver board.
19.
20.
Install shim (if provided) between the reference pin and the optics channel. The shim is attached to the optics
assembly with cellophane tape and should be installed on the same side of the optics that it is taped (e.g. a
shim taped to the left side of the optics should be installed under the left reference pin). Ensure the reference
pins are seated securely against the shim or optics channel (Figure 3-7 on page 3 - 32). Discard the tape.
21.
Install the 4 screws (2 on each side) that hold the optics to the channel.
22.
For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2 screws to
secure.
23.
For visible systems, if the scan lens mask was removed from the channel, replace it with the mask provided
in the kit and tighten the two screws to secure it.
Connect the following cables:
a.
Ground cable.
b.
c.
d.
24.
Remove the shunt from the diode on the laser diode board.
25.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment.)
26.
Check the revision of the AP24507 Main Controller Board. If the revision is lower than E, follow steps 1824 for installation. If it is Rev. E or higher, continue with step 27.
27.
AG11902 Rev. 5
33
28.
Install shim (if provided) between the reference pin and the optics channel. The shim is attached to the optics
assembly with cellophane tape and should be installed on the same side of the optics that it is taped (e.g. a
shim taped to the left side of the optics should be installed under the left reference pin). Ensure the reference
pins are seated securely against the shim or optics channel (Figure 3-7 on page 3 - 32). Discard the tape.
29.
Install the 4 screws (2 on each side) that hold the optics to the channel.
30.
For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2 screws to
secure.
31.
For visible systems, if the scan lens mask was removed from the channel, replace it with the mask provided
in the kit and tighten the two screws to secure it.
Connect the following cables:
a.
Ground cable.
b.
c.
d.
e.
32.
Remove the shunt from the diode on the laser diode board.
33.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup
and calibration procedures. (See Chapter 4 Calibration, Diagnostics, and System Alignment.)
34.
Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously. Press the
NEXT key until the /BEAMON PATH? menu is reached. Select COAXIAL CABLE P1. Press the NEXT
key and save the settings. Proceed with system warmup and calibration.
35.
Replace the system cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
36.
Perform system warmup and calibration as described in Chapter 4 Calibration, Diagnostics, and System
Alignment.
Complete the Optics Defect Tag and attach it to the return optics assembly. Complete all sections of the tag.
2.
Include a sample output from the system, illustrating the problem described on the defects tag.
NOTE: Failure to provide all information on the return tag or to use the appropriate packaging for the returned
optics may reduce your returned parts credit.
34
3.
4.
Make sure the laser diode of the return optics is shunted as described in Section 3.4.1.
5.
6.
Place the return optics in the same packaging materials that held the new optics assembly. Include any foam
or other buffer material around the optics assembly.
7.
8.
Write the RMT number on the outside box containing the return optics assembly. Return optics assemblies
will not be accepted if the RMT number is not written on the outside box.
9.
AG11902 Rev. 5
3.6
Grounding strap
HB1467Allen Wrench Set, 12 Piece (in place of Torx driver for Encoder Housing)
!!WARNING!!
CAUTION
RECORDER CONTAINS
STATIC SENSITIVE COMPONENTS
!!WARNING!!
35
NOTE: Failure to provide all information on the return tag or to use the appropriate packaging for the returned
optics may reduce your returned parts credit.
36
AG11902 Rev. 5
Temperature Strip
82 28
80 27
78 26
76 24
74 23
72 22
70 21
Optics
Assembly
68 20
66 19
64 18
62 17
60 16
58 14
NOTE: Failure to provide all information on the return tag or to use the appropriate packaging for the returned
optics may reduce your returned parts credit.
AG11902 Rev. 5
37
Power down the system. Leave the system plugged into the outlet for earth ground.
2.
Wear a wrist grounding strap and attach it to the jack on the side of the recorder. If necessary, you
may connect the wrist grounding strap to the power supply case after you remove the imagesetter
cover.
Remove the systems back cover by loosening the center screw in back. Lift the rear of the cover
and slide it back, then remove it.
If you were unable to connect your wrist grounding strap to the or banana jack on the imagesetter in
step 2, connect it to the power supply case now.
Install the laser diode shunt (Figure 3 - 9).
3.
4.
5.
Side View
Shunt
Shunted
Unshunted
Unshunted
38
AG11902 Rev. 5
2.
b.
c.
d.
e.
f.
Ground cable.
Remove the scan lens mask (if equipped) by removing the two screws and lifting the cover straight
up.
CAUTION: The optics assembly is heavy. While removing the optics be very careful to support
the assembly, and then pull it up and out toward you while removing it. Do not let the
assembly fall down toward you while removing it up and out of the system. Ensure
that the laser driver board(s) do not hit the base of the system.
3.
4.
Using a 9/64 allen wrench (T-handle) remove three screws from the optical bed plate. Support the
optics assembly to prevent it from falling, then remove the fourth screw (Figure 3 - 4).
Remove the optics assembly and shims.
Screws
Screws
AG11902 Rev. 5
39
Wear a static wrist-strap and ground it to the system as directed in Section 3.6.1.
2.
Place the new optics assembly, scan lens down, on a clean, flat surface.
3.
Remove the protective plastic cap from the spinner motor hole on the new optics assembly.
Motor body
Mirror
Alignment scribe
Figure 3-11 Spinner Motor
4.
With a 5/32" Allen wrench, remove 3 mounting screws from around the Spinner Motor in
the old optics assembly. Support the motor with one hand to prevent it from falling out. Set
the screws and their washers and spacers aside carefully to replace later.
5.
Carefully remove the Spinner Motor by lifting it straight out, being careful to not let the
mirror touch any part of the chassis.
3.6.5.2
NOTE: Do not touch the Spinner Motor Mirror for any reason.
40
1.
2.
Align the scribe mark on the edge of the Spinner Motor with the scribe mark on the housing.
3.
Install and torque the three mounting screws with their washers and spacers to 15 in/lb.
4.
AG11902 Rev. 5
Begin
1
AP24680
Laser Driver
?
5
AC24657
coax
supplied?
Yes
No
17
Firmware
V2.3.2 or
Higher?
No
6
Set Laser
Driver J6 A-B
Yes
2
Firmware
V 2.3.5 or
higher
?
Yes
27
AP24507
rev. E or
higher?
No
No
4
Set J8 to
B-C
Yes
3
Set J8 to
A-B
7
Install shim
between pin
and channel on
side it was
taped
No
18
Remove
AC24657 Coax
8
Install 4 screws
between pin
securing optics
to channel
20
Install shim
between pin
and channel on
side it was
taped
10
Connect:
-Ground cable
-Ribbon cable
to laser driver
-Spinner cables
21
Install 4 screws
securing optics
to channel
12
Remove laser
diode shunt
14
Install cover
22
Install scan
lens mask (if
removed)
Yes
24
Perform spinner
motor encoder
cleaning
15
Install cover
and turn on
power
16
Set front panel
/BEAMON to
RIBBON
CABLE P4
31
Install scan
lens mask (if
removed)
30
Install 4 screws
securing optics
to channel
23
Connect:
-Ground cable
-Ribbon cable
to laser driver
-Spinner cables
11
Perform spinner
motor encoder
cleaning
No
28
Set Laser
Driver J6 B-C
29
Install shim
between pin
and channel on
side it was
taped
19
Set Laser
Driver J6 A-B
9
Install scan
lens mask (if
removed)
13
Firmware
V2.3.2 or
Higher?
Yes
25
Remove laser
diode shunt
26
Install cover
32
Connect:
-Ground cable
-Ribbon cable
to laser driver
to laser driver
-Spinner cables
33
Perform spinner
motor encoder
cleaning
34
Remove laser
diode shunt
35
Install cover
and turn on
power
36
Set front panel
/BEAMON to
COAXIAL
CABLE P1
(Cal menu)
AG11902 Rev. 5
41
Check the optics to see if an AP24680 laser driver board is installed. Note: AP24680 laser driver
boards are used on visible systems only.
If an AP24680 is installed, proceed with step 2.
2.
3.
4.
5.
6.
7.
IMPORTANT:
Remove the old shims and replace them with the new shims that are shipped with
the new optics assembly. Using the old shims with the new optics assembly could
cause a System Error 2. Keep the old shims with the old optics.
mask
Possible
Shim Location
Pin
Pin
2 (see text)
Possible
Shim Location
2 Mounting Screws
2 Mounting Screw
42
AG11902 Rev. 5
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Install the 4 screws (2 on each side) that hold the optics to the channel.
For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2
screws to secure.
For visible systems, if the scan lens mask was removed from the channel and the mask IS NOT a 2
inch mask (see Figure 3 - 13), replace it with the mask provided in the kit and tighten the two
screws to secure it.
Connect the following cables:
Ground cable.
Ribbon cable to P1 of the Laser Driver Board.
Spinner cable to AP27231/AP28495 J3, Speedring PCB, if present.
Spinner cable to AP24507 P12, Main Controller PCB. (21K/32K systems.)
Spinner cable to AP999P2/AP24507 P15 main controller PCB (10.5K/16K systems).
Remove the shunt from the diode on the laser diode board.
Check the firmware version on the AP24507. If the version is lower than 2.3.2, proceed with step
14. If it is version 2.3.2 or higher, proceed with step 15.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup (Section 3.6.7) and calibration (Section 3.6.8) procedures.
Replace the systems cover as described in Section 3.4.2 and turn the power on.
Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously.
Press the NEXT key until the /BEAMON PATH? menu is reached. Select RIBBON CABLE P4.
Press the NEXT key and save the settings. Proceed with system warmup and calibration.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup (Section 3.6.7) and calibration (Section 3.6.8) procedures.
If the optics assembly was supplied with an AC24657 coax BEAMON cable attached to P5 of the
laser driver PCB, check if the AP24507 firmware version is 2.3.2 or higher. If it is not version 2.3.2
or higher, proceed to step 18. If the firmware version is 2.3.2 or higher, proceed with step 26.
If the AP24507 firmware version is lower than 2.3.2, do not use the AC24657 coax BEAMON
cable. Remove the coax cable from P5 of the laser driver board.
Set jumper J6 on the laser driver board to the A-B position.
Install shim (if provided) between the reference pin and the optics channel. The shim is attached to
the optics assembly with cellophane tape and should be installed on the same side of the optics that
it is taped (e.g. a shim taped to the left side of the optics should be installed under the left reference
pin). Ensure the reference pins are seated securely against the shim or optics channel (Figure 3-13
on page 3 - 42). Discard the tape.
Install the 4 screws (2 on each side) that hold the optics to the channel.
For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2
screws to secure.
For visible systems, if the scan lens mask was removed from the channel and the mask IS NOT a 2
mask (see Figure 3 - 13), replace it with the mask provided in the kit and tighten the two screws to
secure it.
Connect the following cables:
Ground cable.
Ribbon cable to P1 of the Laser Driver Board.
Spinner cable to AP27231/AP28495 J3, Speedring PCB, if present.
Spinner cable to AP24507 P12, Main Controller PCB. (21K/32K systems.)
Spinner cable to AP991/AP24507 P15 main controller PCB (10.5K/16K systems).
Remove the shunt from the diode on the laser diode board.
Replace the cover as described in Section 3.4.2 and verify operation.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup (Section 3.6.7) and calibration (Section 3.6.8) procedures.
AG11902 Rev. 5
43
38.
39.
40.
41.
42.
43.
44.
45.
46.
Check the revision of the AP24507 Main Controller Board. If the Rev. is lower than E, follow steps
18-24 for installation. If it is Rev. E or higher, continue with step 27.
Set jumper J6 on the laser driver board to the B-C position.
Install shim (if provided) between the reference pin and the optics channel. The shim is attached to
the optics assembly with cellophane tape and should be installed on the same side of the optics that
it is taped (e.g. a shim taped to the left side of the optics should be installed under the left reference
pin). Ensure the reference pins are seated securely against the shim or optics channel (Figure 3-13
on page 3 - 42). Discard the tape.
Install the 4 screws (2 on each side) that hold the optics to the channel.
For IR systems if a scan lens mask was removed from the channel, replace it and tighten the 2
screws to secure.
For visible systems, if the scan lens mask was removed from the channel and the mask IS NOT a 2
mask (see Figure 3 - 13), replace it with the mask provided in the kit and tighten the two screws to
secure it.
Connect the following cables:
a. Ground cable.
b.
c.
d.
e.
f.
Remove the shunt from the diode on the laser diode board.
You have finished the procedure. Replace the systems cover (Section 3.4.2) and perform the system warmup (Section 3.6.7) and calibration (Section 3.6.8) procedures.
Enter the calibration menu by pressing the PREV and MENU front panel keys simultaneously.
Press the NEXT key until the /BEAMON PATH? menu is reached. Select COAXIAL CABLE P1.
Press the NEXT key and save the settings. Proceed with system warmup and calibration.
Ensure that the power cord is firmly attached to the system and that it is plugged into an appropriate
outlet, then turn on the system power.
2.
NOTE: If a System Error 2 occurs, power down, attach a wrist grounding strap, remove the cover, check the optics
assembly cable connections, and make sure the shunt is removed. Also ensure that the proper shims have
been installed. If the System Error 2 continues, contact ECRM Customer Service.
NOTE: If the first image output is blank, attach the wrist grounding strap, remove the cover, and make sure the
diode is not shunted.
3.6.8 Calibration
After a 30 minute warm-up period the system is ready to be calibrated for the new optics
assembly. Test pattern #4 will be used for calibration measurements. The Calibration
Menu will be used to adjust Image Centering, Pel Correction, and Line Correction.
44
AG11902 Rev. 5
3.6.8.1
Press MENU.
2.
3.
4.
5.
Press NEXT.
6.
7.
8.
Set EXPOSURE VALUE to 210. This value may need to be adjusted depending on the
type of media used. If the test pattern is too light, increase the exposure. If the test pattern
is too dark, decrease the exposure.
9.
10.
Press NEXT.
3.6.8.2
Calibration Menu
The Calibration menu provides the service technician with procedures for calibrating the
Image Centering, Pel Correction and Line Correction. To enter the Calibration Menu,
from the Online or Offline window, press and hold the Prev Key and then press the Menu
Key. The Calibration Menu will appear. Refer to the Calibration Menu Map (Figure 3 14) for the following procedure.
When you enter values from the keypad, PREV and NEXT move the cursor left and right
respectively, and SELECT changes the value of a selected field.
NOTE: The calibration measurements in this document appear in metric units. In the System Setup menu, change
the measuring units to Metric before proceeding with the instructions in the following sections.
If necessary, change the units to Metric in the System Setup menu as follows:
1.
At the Online prompt, press MENU to access the System Setup menu.
2.
Press NEXT to view the English/Metric display, which is the first System Setup menu
option.
3.
4.
Keep pressing NEXT until the Save System Setup? prompt appears.
5.
6.
Press NEXT to exit the System Setup menu: Online appears in the display.
Remember to change the units back to English when you are finished working on the system.
NOTE: All values on the display screen appear in hundredths of a millimeter (.01mm), so that you can enter values
as whole integers without adding a decimal place. For example, a value of 27.35mm appears as 2735 on
the display.
AG11902 Rev. 5
45
NOTE: To access
the Calibration menu,
from the Online/
Offline window:
ONLINE/OFFLINE
PREV
IMAGE CENTERING
SHIFT RIGHT
SELECT
IMAGE CENTERING
SHIFT LEFT
NEXT
NEXT
IMAGE CENTERING
VALUE IN 0.01 mm
IMAGE CENTERING
VALUE IN 0.01 mm
SHIFT RIGHT
BY (0-4064):####
SHIFT LEFT
BY (0-4064):####
NEXT
NEXT
PEL CORRECTION
VALUE IN 0.01mm
CALIBRATION DEFAULT VALUES IN METRIC
PREV
EXPECTED VALUE
45000
WINDOWS
Mako 36XX
Mako 46XX
762
762
..
35000
*
30000
..
45000
*
..
YES/NO
YES/NO
4064
4064
..
45000
*
..
60000
*
..
YES/NO
YES/NO
NEXT
IMAGE CENTERING SHIFT RIGHT
IMAGE CENTERING SHIFT LEFT
PEL CORRECTION VALUE
EXPECTED VALUE
ACTUAL VALUE
LINE CORRECTION VALUE
EXPECTED VALUE
ACTUAL VALUE
USE SPOT DOUBLER
IGNORE SYSTEM ERRORS
SAVE CALIBRATION
ACTUAL VALUE
#####
NEXT
LINE CORRECTION VALUE
IN 0.01mm
NEXT
EXPECTED VALUE
60000
*Actual values are calculated from the measured values when running test
patterns.
**Example values in the chart are for Mako 4650 only.
NEXT
ACTUAL VALUE
#####
NEXT
IGNORE SYSTEM ERRORS?
NO
SELECT
NEXT
NEXT
/BEAMON PATH?
COAXIAL CABLE P1
SELECT
/BEAMON PATH?
RIBBON CABLE P4
NEXT
NEXT
LASER DIODE BIAS
% (0-100): 100
NEXT
SAVE CALIBRATION SETUP?
NO
NEXT
SELECT
ONLINE/OFFLINE
46
AG11902 Rev. 5
3.6.8.3
Image Centering
Refer to the Calibration Menu Map (Figure 3 - 14) for the following procedure. When you enter
values from the keypad, PREV and NEXT move the cursor left and right respectively, and SELECT
changes the value of a selected field.
To set the image centering, output a test pattern and measure the distance from the edge of the test
pattern to the edge of the media.
1.
Press the SELECT key to start test pattern #4. The system should display Recording
Image.
2.
3.
4.
If the test pattern is cut off on the left or right side of the output, make an initial centering
adjustment as described below and output the test pattern again (make all measurements in
millimeters):
a. Calculate: X = ((Film Width - Expected grid width)/2) * 100
b.
c.
d.
e.
*Example values:
Existing margin
Emulsion Up
Trailing Edge
NOTE: For a Mako 36 the film width is usually 355mm, and the grid width is usually 350mm. For a Mako 46 the
film width is usually 460mm, and the grid width is usually 450mm.
AG11902 Rev. 5
47
This initial adjustment results in an image that appears entirely on the film and requires a
minimal adjustment to become perfectly centered. When the entire test pattern appears
between the left and right sides of the output, complete the following steps to center the
image.
5.
Measure the distance between the left edge of the film and the left edge of the test pattern
in millimeters.
6.
Measure the distance between the right side of the film and the right side of the test pattern
in millimeters.
7.
Calculate the difference between these two values and divide by 2, then multiply by 100.
Apply any initial adjustment. This is the image centering value.
8.
Use the calibration menu map in Figure 3 - 14 to access the current Image Centering
value.
9.
Apply the image centering value to the current Shift Left or Shift Right value, as
required to center the grid on the film. For Example, if Shift Left is selected and the
image is too far to the left, subtract from the Shift Left value. If Shift Right is selected
and the image is too far to the left, add to the Shift Right value.
Smaller distance
Greater distance
Trailing edge,
emulsion side up
Save the calibration setup as described on the menu map in Figure 3 - 14.
11.
Output the test pattern and measure the image centering value again. If the new image centering value is greater than 1.0mm, repeat this procedure and add or subtract as needed the
correction value to the existing image centering value.
3.6.8.4
Pel Correction
Pel correction adjusts the width of the image. Using the centered output from Section 3.6.8.3, perform the following:
48
1.
2.
Calculate the error by finding the difference between the test pattern width and the
expected width of the test pattern (Figure 3 - 17). The pel correction value is the measured
error in millimeters, multiplied by 100.
3.
Apply the pel correction value to the current Pel Correction ACTUAL VALUE.
AG11902 Rev. 5
If the grid is too narrow, subtract the pel correction value from the ACTUAL VALUE. If the grid is too wide,
add the pel correction value to the ACTUAL VALUE
Pel Correction
ACTUAL VALUE
Figure 3-17 Pel Correction
3.6.8.5
Line Correction
Line correction adjusts the length of the image. Make sure the Pel correction is within specification before
adjusting the line correction.
1.
Press the SELECT key to run test pattern 4. Wait until the test pattern is complete and the display no longer
indicates RECORDING IMAGE.
2.
Calculate the error by finding the difference between the test pattern length and the expected length of the test
pattern (Figure 3 - 18). The line correction value is the measured error in millimeters, multiplied by 100.
3.
Apply the line correction value to the current Line Correction ACTUAL VALUE.
If the grid is shorter than the expected value, subtract the line correction value from the ACTUAL VALUE. If
the grid is longer than the expected value, add the line correction value to the ACTUAL VALUE.
Line Correction
ACTUAL VALUE
AG11902 Rev. 5
49
3.6.8.6
Checking Perpendicularity
Press SELECT key to run test pattern 4. Wait until the test pattern is complete and
the display no longer indicates RECORDING IMAGE.
Emulsion up!
Emulsion up!
trailer
shim NON power supply side
50
Place the image on a flat surface, emulsion up with the trailer toward you.
Measure diagonally in both directions across the image.
Find the difference between the two measurements (long diagonal - short diagonal).
If the measurement is greater than 0.19mm use shims to raise the side of the
optics indicated in Figure 3 - 19, as described in Section 3.6.8.7.
AG11902 Rev. 5
3.6.8.7
Installing Shims
Use a shim whose thickness equals the perpendicularity measurement difference, or use multiple shims whose
total thickness equals the perpendicularity measurement difference. Shims should only be required on one side of
the optics.
1.
2.
Use a 9/64 allen wrench (T-handle) to loosen the four screws on the optical bed plate, which
secure the optics assembly to the rail bracket of the imagesetter. Do not remove.
Place the shim(s) between the pin of the optics assembly and the optics channel
3.
Pin
Pin
Possible
Shim Location
Possible
Shim Location
2 Mounting Screws
2 Mounting Screws
2.
3.
4.
5.
6.
AG11902 Rev. 5
51
Complete Optics Defect Tag and attach it to the return optics assembly. Complete all sections of the
tag.
2.
Include a sample output from the system, illustrating the problem described on the defects tag.
NOTE: Failure to provide all information on the return tag or to use the appropriate packaging for the returned
optics may reduce your returned parts credit.
3.
4.
5.
6.
7.
8.
9.
52
AG11902 Rev. 5
3.7
NOTE: Replacing either one of the belts or both, require the same procedure.
1.
2.
3.7.1.1
Removing Belts
Remove the cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
Release three screws holding the drive motor bracket to the drive (Figure 3-21), and slide the whole motor
assembly up.
Fast belt
Slow belt
Screws (3 Places)
Release 2 screws through the holes in the pulley and slide the whole assembly to the left.
4.
Remove the slow belt first and the fast belt next, if necessary.
1.
3.7.1.2
Replacing Belts
Replace the Fast belt first and the Slow belt last.
2.
Tighten the slow belt to10 to 15 lbs by sliding the pulley assembly to the right and tightening the two screws
through the holes. Use belt tension gage AX0073 to verify tension.
3.
Tighten the fast belt to 10 to 15 lbs by sliding the drive motor assembly down and tighten the three screws.
Use belt tension gage AX0065 to verify tension.
AG11902 Rev. 5
53
4.
Check that the slow belt is centered on the pulley. If necessary, slide the pulley on its shaft by releasing 4 set
screws and retighten in the centered position.
Slow Belt
Idler Pulley
Fast Belt
Figure 3-22 Kapton Belt Drive Tension Gauges (AX0073/AX0065)
54
5.
Power up and run the drive motor. Press the PREV, NEXT, AND MENU buttons simultaneously to access
the System Alignment menu. Press SELECT for Belt Alignment, then press NEXT. The Hit Advance
Start Film window will be displayed. Press the ADVANCE key and the Drive motor will run until you press
the STOP key. This is done to check that the fast belt is centered on the large pulley. If necessary, adjust
screws while running until the belt is centered and stable.
6.
Replace the cover when belt replacement is complete. (See 3.4.2 Replacing the Imagesetter Cover on page 3
- 27).
AG11902 Rev. 5
3.8
1.
3.8.1.1
Removing Belts
Remove cover (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2.
Disconnect connector (P14) on the Main Controller board. Take the fast Belt, out of the way. Refer to
Figure 3-21 Kapton Drive Belts. Release 2 screws and slide the whole motor assembly to the left.
3.
Remove 3 screws to the drive motor bracket. Carefully remove motor with bracket.
4.
Remove the four screws to the drive motor (Figure 3-21 Kapton Drive Belts). Remove the motor.
1.
3.8.1.2
Replacing Belts
Replace with new motor. Reconnect P14 on the Main Controller board.
2.
Refer to 3.7 Replacing the Belts on page 3 - 53 (Step 3 and Step 4) to tighten and align the Fast Belt.
3.
Replace cover (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
1.
3.8.2.1
Removing Motor
Remove cover (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2.
Disconnect connector (P14) on the Main Controller board. Take the Fast belt out of the way (See Figure 322 Kapton Belt Drive Tension Gauges (AX0073/AX0065)). Release 2 screws and slide the whole motor
assembly to the left.
3.
Remove 2 screws to the drive motor bracket. Carefully remove motor with bracket.
4.
Remove the four screws to the drive motor. Remove the motor.
1.
3.8.2.2
Replacing Motor
Replace with new motor. Reconnect P14 on the Main Controller board.
2.
Refer to section Section 3.7.1.2 on page 3 - 53 to tighten and align the Fast Belt.
3.
Replace cover (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
AG11902 Rev. 5
55
3.9
Remove the cover (Refer to 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2.
Pull off the plastic cutter shield from the front of the cutter assembly. A hook-and-loop fastener strip holds
the cutter shield in place.
3.
4.
5.
6.
Slide the cutter assembly to the left and pull it out of the system.
7.
8.
9.
10.
11.
Attach the plastic cutter shield to the front of the cutter motor.
12.
Replace the cover (Refer to 3.4.2 Replacing the Imagesetter Cover on page 3 - 27).
Screws (4 places)
Cutter Motor
Connectors
Sensor Connectors
Figure 3-23 Cutter Assembly
56
AG11902 Rev. 5
The start of line adjustment for standard speed optics is performed at ECRM and should not be necessary in
the field. DO NOT ADJUST SOL unless you are installing a filter kit or changing the laser pre-bias.
This procedure applies only to Mako 3600, 3625, 4600, and 4625 systems (AKA Mako 36/46). There is no SOL adjustment for
Mako 3650, 3675, 4650 and 4675 systems (AKA Mako 36/46 with High Speed Option).
CAUTION:
This procedure requires an oscilloscope. Adjusting SOL without an oscilloscope may damage the laser diode.
Required materials:
Wrist grounding strap
Oscilloscope
HB0523 Tweeker, Large 3/32
The optics assembly must be at least 62F (17C) before you perform this procedure (See !WARNING! on page 9).
CAUTION:
Failure to allow optics temperature to stabilize or machine to warm up may cause SYSTEM ERROR #2, jitter,
or displaced data in image.
1.
2.
4.
AP24507 - TP11
Connect Channel #2 of the Oscilloscope to:
5.
AP24507 - TP12
Set scope sensitivity to 1V/DIV for both channels, time base to 2 microseconds/DIV, internal trigger to Channel #1, and
trigger on the positive edge.
6.
7.
8.
9.
If a SYSTEM ERROR #2 is displayed, adjust Laser Driver pot R33 one revolution CCW and press PREV to restart.
10.
Repeat step 6 until SYSTEM ERROR #2 is no longer displayed. If SYSTEM ERROR #2 cannot be cleared, the Laser
Diode may be defective. Make sure the diode is not shunted.
11.
12.
Under the USER SETUP menu, select TEST PATTERNS and select TEST PATTERN 0.
13.
14.
AG11902 Rev. 5
57
15.
Press SELECT to start Test Pattern 0. The machine responds RECORDING IMAGE / FILM COUNT n.n.
Channel #1
Channel #2
58
16.
Adjust laser Driver pot R33 until the peak voltage on Channel #1 is 4V +/- 0.1V for IR machines, and 2V+/0.1V for visible machines. See Figure 3-24. Never allow voltage on Channel #1 to exceed 10 V or damage
to the diode may occur.
17.
18.
19.
20.
21.
AG11902 Rev. 5
Allow the machine to be powered on for at least 30 minutes before making the following adjustments.
2.
Run the standard droop test. For field use, run Test Pattern #2.
3.
Ensure that you are properly grounded using the wrist strap. Power down the system.
4.
Remove the top cover. Defeat the interlocks with SW0212. Power up the system.
5.
If reverse droop is detected, rotate R41 CW one turn (Figure 3-25). If normal droop is present, rotate R41
one turn CCW.
50% tint
Normal Droop
50% tint
Reverse Droop
Figure 3-25 Droop Examples
6.
Repeat steps 2 to 5 until the reverse droop or normal droop is at an acceptable level.
7.
Power down the system, remove the interlocks, and replace the cover as described in 3.4.2 Replacing the
Imagesetter Cover on page 3 - 27.
Power on the machine for at least 30 minutes before making the following adjustments.
2.
Run the standard droop test (For field use, run TEST PATTERN #2.)
3.
Ensure that you are appropriately grounded using the wrist strap.
4.
Power down the system. Remove the top cover. Defeat the interlocks with SW0212. Power up the system.
5.
6.
Place positive probe of a DVM onto TP1. Place the ground probe on ground of the Laser Driver board.
7.
8.
9.
10.
Repeat steps 8 and 9 until the droop is at the acceptable. If you cannot get the droop to reach an acceptable
level call Customer Service.
AG11902 Rev. 5
59
2.
Remove cover (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.). Unplug the AC cable from the
side of the power supply.
P25 Connector
(to AC21721 power for
SCSI/Pel Board)
P1 Connector
P24 Connector
Install the laser diode shunt (See Figure 3-1 on page 26.)
4.
5.
Disconnect the P24 connector from the interlock cabling. If the system is a non- interlock system, save the
shorting plug for reinstallation on new power supply assembly.
6.
7.
Remove and set aside the 4 nuts from bottom of assembly (Figure 3-27).
4 Nuts
(At the base of the
power supply.)
60
8.
9.
10.
11.
12.
Reconnect P24 to Interlock cable (on a non-interlock system, reinstall shorting plug to P24).
AG11902 Rev. 5
13.
14.
15.
16.
Replace cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.).
2.
With the power switch off, there should be No continuity between any two terminals of the AC mains input.
Check for continuity between the ground terminal of the AC mains input and any exposed metal of the imagesetter Base Tray. There should be no more than 0.50.
3.
Turn the power switch on. There should be a high impedance between the Hot and Neutral terminals; minimum of 700k. Also, insure there is no continuity between the Ground terminal and either the Hot and Neutral terminal.
4.
Voltage
P1 Connector
Tolerance
+5BV
PIN 1,2
+0.25V/-0V
+24V
PIN 5
+1.2V
+15V
PIN 7
+0.45V
-15V
PIN 9
+0.45V
GND
PIN 3, 4, 6, 8, 12
1.
With the power supply installed and connected to the system, turn on the power.
2.
Turn the rear adjustment POT until 5V is within the specified range.
3.
Verify that 24V is within the specified range. If it is not, turn the rear adjustment POT until both 5V and 24V
are within the specified range.
NOTE: Turning the rear adjustment POT adjusts both 5V and 24V. After adjusting one it is necessary to check the
other to ensure that it is still within the range specified.
AG11902 Rev. 5
61
-15 Adjust
+15 Adjust
5 Volt/24 Volt Adjustment
(sets 5 volts located on
rear of power supply)
62
4.
Place the adjustment tool HB1425 through the lower hole on the side of the power supply and engage the
lower POT on the power supply PC board. Turn the adjustment POT until +15V is within the range specified.
5.
Place the adjustment tool HB1425 through the upper hole on the side of the power supply and engage the
upper POT on the power supply PC board. Turn the adjustment POT until -15V is within the range specified.
AG11902 Rev. 5
3.13.1 Removal
1.
2.
Remove cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
3.
4.
5.
6.
7.
8.
Remove the six screws securing the AP9992P2 to the standoffs and remove the board.
3.13.2 Replacement
1.
Ensure that all necessary cabling, firmware, etc. is installed on the main controller board before installation
of the AP9992P2.
2.
Place the AP9992P2 board on the standoffs with P1 and P2 toward the rear of the machine.
3.
4.
5.
6.
7.
8.
Install cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.).
AP9992 Board
AG11902 Rev. 5
63
Service Technicians should always wear a grounded static wrist strap prior to performing any
removal, replacement or alignment procedures.
1.
Remove cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2.
3.
Remove AP9992 SCSI/PelBox Interface Board (Refer to 3.13 SCSI/PelBox Interface Board (AP9992P2) on
page 3 - 63).
4.
Remove connector P4 from main controller board first. (This will reduce the possibility of static damage to
the laser diode.)
5.
6.
Remove and set aside the screws that fasten the board to the optics housing.
7.
Noting the orientation of the board, lift and remove the main controller board from the PelBox.
8.
If the three standoffs shown in Figure 3 - 30 exist, put black electrical tape over the three standoffs indicated
to prevent electrical shorts.
3 Standoffs
10.
Reconnect the P10 Power Supply connector first. Reconnect the rest of the connectors, reconnecting the P4
connector last.
11.
Select the appropriate EPROMs and install in the U301 and U302 locations, as described in the EPROM
replacement procedure enclosed with the new controller board.
12.
13.
14.
CAUTION:
64
b.
Observe the control panel display and adjust R21 of the 9991 (R17 of the AP24507P3) for the best contrast with a minimal amount of black background.
c.
Power down.
Replace cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
DO NOT REMOVE LASER DIODE SHORTING PLUG WITH POWER ON
AG11902 Rev. 5
Remove cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
2.
3.
4.
5.
6.
7.
8.
Replace cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
NOTE: If the LCD display requires an intensity adjustment, refer to Section 3.14, step 13. LCD Display Adjustment:
AG11902 Rev. 5
65
Remove the cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
2.
Remove the screws connecting the cables to the cover, so the cover hangs fully open. This step makes it easier to perform the rest of the procedure.
3.
4.
5.
a.
b.
c.
Use a marker to index the locations of the four screws retaining the input cassette shelf.
d.
Remove the four screws locating the input cassette shelf on the drive roller assembly.
e.
Remove the EOM senor connector from the EOM sensor assembly (on the underside of the input cassette shelf) and remove the input cassette shelf from the imagesetter.
6.
a.
Loosen the three screws on the drive motor bracket, but do not remove them.
b.
Slide the motor up and loosen the Kapton belt. Let the Kapton belt and the drive motor hang loosely in
place.
Vertically line up the two holes in the idler pulley and loosen the tension on the idler pulley by loosening
the two screws visible through the holes.
Black belt
Drive pulley
Idler pulley
Motor bracket screws
Kapton belt
Bracket with motor
Figure 3-31 Capstan Assembly
7.
b.
c.
Remove the screw and washer from the end of the idler pulley shaft.
d.
Loosen the two hub set screws and remove the idler pulley and wave washer from its shaft. Save the
wave washer.
e.
Remove the left and right laser shields from the drive assembly.
f.
Remove the two screws securing the idler bearing with shaft and remove them from the drive.
g.
Remove the four hub set screws that hold the drive pulley to the drive assembly and remove the drive
pulley. Two hub set screws are located on either side of the drive pulley.
66
Remove the drove motor cable from P14 of the controller board.
AG11902 Rev. 5
8.
b.
Remove the 3 screws holding the drive motor bracket to the drive.
c.
b.
Remove the outside encoder connector P2 from the main controller board.
c.
On standard speed systems, remove the bolt holding the SOL detector to the drive assembly and remove
the SOL detector (Figure 3-32). Note that the SOL detector is pushed against the side of the drive
assembly and must be replaced like this. (There is no SOL sensor on high speed systems.) Note that on
Mako 3600 systems the SOL detector is mounted to the right of other systems. It must be replaced by
using the Alignment block (FX0919) that is found in the tool kit. To replace the SOL on the Mako
3600s, place the SOL under the drive cross bar (Figure 3-33) and loosely attach it with the SOL detector
mounting screw. Then place the Alignment block (FX0919) under the drive cross bar and SOL, and
position it on the edge of the drive cross bar. Then tighten the SOL detector mounting screw until it is
firmly in place. Place the Alignment block in the tool box.
Alignment Block
Figure 3-33 SOL Detector for the Mako 3600 and Mako 3625 (AKA Mako 36)
d.
AG11902 Rev. 5
Hold the drive assembly while you remove the four bolts that secure it onto the channel (two on top and
two in front). Hold the drive assembly while you remove the bolts so the assembly doesnt fall out. Lift
67
Channel
Place the new drive into the channel and install the four mounting bolts very loosely, not tight enough to
grip the drive in any way. Make sure the drive contacts the channel evenly on the front and top.
Mounting screws
(both sides)
Tighten these screws first
Figure 3-35 Drive Assembly and Channel
10.
b.
Carefully tighten the two front mounting bolts, making sure that the top cross bar does not lift off of the
channel.
c.
Tighten the two top bolts securing the drive to the channel, ensuring that the drive does not show any
signs of warping. Note: If you experience any difficulty tightening the two top bolts, if they bind or if
the drive or any part of it visibly bends during the tightening, call ECRM Customer Service.
d.
On standard speed systems, replace the SOL sensor assembly and the screw that holds it to the left side
of the drive assembly. (There is no SOL sensor assembly on high speed systems.)
e.
f.
g.
Take the four mounting bolts from the front of the old drive and install them onto the new drive. These
bolts hold the cutter assembly when you attach it in step 14.
68
Attach the drive motor and bracket to the drive and loosely insert the three screws that secure the
bracket.
AG11902 Rev. 5
b.
11.
Connect the drive motor cable to P14 of the main controller board.
Mount the idler bearing with shaft onto the new drive assembly and loosely install the two screws into it
(Figure 3-31).
b.
Install the wave washer and then the idler pulley onto the idler pulley shaft. Align the shaft flats with the
two hub set screws on the idler pulley, while you push the idler pulley onto the shaft. Compress the
wave washer 2/3 to 3/4 and tighten the two hub set screws.
c.
Install the screw and washer onto the end of the idler pulley shaft.
d.
Install the drive pulley on the roller shaft of the new drive assembly. Set the drive pulley just clear of the
idler pulley, align the flats of the roller shaft with the hub set screws, and tighten the hub set screws.Two
hub set screws are located on either side of the drive pulley
e.
Reinstall drive belts and align them per Section 3.7 on page 3 - 53.
12.
Reinstall the laser shields on the left and right sides of the drive assembly.
13.
b.
Attach the EOM sensor connector to the EOM assembly on the rear of the shelf.
c.
Connect the four screws that hold the input cassette shelf to the drive roller assembly. Make sure the
four screws line up with the indexes you made in step 4c.
d.
Connect the ground strap from the chassis to the input cassette shelf.
e.
f.
For a Mako series imagesetter with a slotted input cassette shelf, align the shelf as described in section
3.17 Input Cassette Shelf Alignment Procedure on page 3 - 70.
14.
Reinstall the cutter assembly. (Refer to the cutter replacement procedure Section 3.9 on page 3 - 56.)
15.
Reconnect the cables to the left and right sides of the cover.
16.
Replace the cover. (See 3.4.2 Replacing the Imagesetter Cover on page 3 - 27.)
AG11902 Rev. 5
69
Remove the imagesetter cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
2.
Remove the screws connecting the cables to the cover, so the cover hangs fully open. This step makes it easier to perform the rest of the procedure.
3.
4.
Remove the two top screws that hold the cutter assembly to the imagesetter.
5.
6.
Insert one shelf alignment tool (AX0094) on the left side of the cassette shelf so that its pin fits inside the
left-most reference slot on the cassette shelf. Make sure the left screw hole on the tool aligns with the top
screw hole on the film drive side plates.
70
7.
Insert the other shelf alignment tool (AX0094) on the right side of the cassette shelf so that its pin fits in the
right-most reference slot on the cassette shelf. Make sure the right screw hole on the tool aligns with the top
screw hole on the film drive side plate.
8.
Insert a cutter assembly screw into each of the shelf alignment tools, to secure them to the input cassette
shelf. As you tighten the shelf alignment tools in place the input cassette shelf becomes perfectly positioned
in the imagesetter.
9.
Insert screws into the two accessible screw holes on the cassette shelf. Only the top screw holes are accessible because the lower holes are covered by the shelf alignment tools.
10.
Remove the cutter assembly screws from the shelf alignment tools and remove the tools from the cassette
shelf.
11.
Insert the two cutter assembly screws back into the top holes of the film drive side plates.
12.
Insert the remaining two screws into the bottom holes of the input cassette shelf.
13.
14.
15.
Replace the imagesetter cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26).
AG11902 Rev. 5
1.
2.
Refer to Section 4, Menu Operation, in the Mako Series Operator Guide, AG11792, for instructions on how
to use the Calibration menu, System Setup Menu, and User Setup menu. Record the current values for the
menu options listed below:
Table 3-2: Menu Selections to Verify
Calibration Menu
1. English/Metric
1. Interface Mode
2. Media Type
2. Resolution
2. Pel Correction
3. Line Spacing
3. Media Width
3. Line Correction
4. Overscan
4. Spinner Type
5. Counter Display
6. BEAMON Path
7. Image Offset
8. Spinner Timeout
6.
7.
Remove the cover. (See 3.4.1 Removing the Imagesetter Cover on page 3 - 26.)
CAUTION:
Failure to wear a ground strap can result in damage to sensitive electronics in your imagesetter.
Do not attempt to complete this procedure without doing so.
Failure to install the laser diode shunt during this operation can result in damage to the laser diode.
8.
Remove the AP9992 SCSI/PelBox Interface Board (Refer to Section 3.13 SCSI/PelBox Interface Board
(AP9992P2) on page 3 - 63.
AG11902 Rev. 5
71
9.
Using an IC extractor tool, locate and remove the EPROMs from their sockets on the Main Controller
Board. Table 1 lists the EPROM part number and Main Controller Board reference designator for each system type.
Table 3-3: Mako Series EPROM Identification*
Imagesetter
Series
Reference
EPROM Part
Number
Mako 3600
AP24507P3
U-302
U-301
JA1032
JA1033
Mako 3625
(AKA Mako 36)
AP24507P3
U-302
U-301
JA1053
JA1033
Mako 3650
AP24507P3
U-302
U-301
JA1035
JA1037
Mako 3675
(AKA Mako 36 with High
Speed Option)
AP24507P3
U-302
U-301
JA1053
JA1037
Mako 4600
AP24507P3
U-302
U-301
JA1032
JA1034
Mako 4625
(AKA Mako 46)
AP24507P3
U-302
U-301
JA1053
JA1034
Mako 4650
AP24507P3
U-302
U-301
JA1035
JA1036
Mako 4675
(AKA Mako 46 with High
Speed Option)
AP24507P3
U-302
U-301
JA1053
JA1036
72
10.
Install the Updated EPROM into the appropriate socket, paying close attention that the 'u' notch on the
replacement EPROM is aligned with the 'u' notch on printed circuit board mask.
11.
Replace the AP9992 SCSI/PelBox Interface Board (Refer to 3.13 SCSI/PelBox Interface Board (AP9992P2)
on page 3 - 63).
12.
13.
Upon power up, a message "EPROM ERROR #n Press PREV to continue" is displayed. (The imagesetter
system calibration and set-up data need to be reinitialized.) Press the PREV key to re-initialize the imagesetter.
14.
Refer to Chapter 4 Calibration, Diagnostics, and System Alignment for instructions to access the Calibrating
menu. The EPROM Installation is Complete.
AG11902 Rev. 5
Remove cover.
2.
3.
4.
5.
6.
Remove encoder.
7.
Do not restore centering slide into encoder housing. This may result in damage to encoder disk.
CAUTION:
With two fingers, front and back, rotate Hub until setscrew aligns with slot in PC board. This
allows the allen wrench to fit into the setscrew without touching the PC board. (Slide lock
mechanism needs to be pushed in slightly, but not all the way, to allow hub to rotate freely.)
Pull Slide Lock Mechanism out to fully extended position to lock the Hub in the correct position. Refer to Figure 2.
Slide Lock
mechanism
pull out
setscrew
AG11902 Rev. 5
73
2.
Verify encoder mount FA21415 is Rev 2 or later (Figure 3-38). Change the encoder mount assembly
(AO21572) if necessary.
3/8
Encoder Mount
(FA21415)
Figure 3-38 Checking the Encoder Mount
3.
Align Hub with Shaft and gently push Hub onto Shaft until Encoder is resting on mounting surface. Push on
Hub only, not on the PC board or the Encoder Body.
4.
5.
Maintain pressure on Hub to insure it is seated in centering mechanism and secure Hub to Shaft by rotating
setscrew clockwise, using long leg of allen wrench, until setscrew makes contact with Shaft. Note: The flat
on the shaft must be lined up with the set screw in the hub before tightening.
6.
Note the position of the short leg of the allen wrench and rotate an additional 1/4 turn clockwise to apply
approximately 20 oz-in torque.
7.
8.
INSPECTION: Verify that a gap exists between the disk and the mask by inserting a .010 plastic shim in
gap on the underside of the PC board (see Figure 3). Rotate roller slowly one revolution, gently moving
.010 shim (or equivalent) to verify no binding exists. If a .010 minimum gap does not exist, remove and reinstall the Encoder.
CAUTION:
9.
Do not rotate roller without first verifying the gap between mask and disk. Any disk contact with
mask may result in disk/mask damage and encoder replacement.
Install Cover. If Cover has through-hole option, align mylar seal with Shaft and slide Cover over Encoder
body until the tabs on the base engage with the locking features in the cover. Care must be taken when
installing through-hole cover onto a stepped shaft.
Hub
PC board
disk
base
mask
insert .010 shim
in this gap
74
AG11902 Rev. 5
Introduction
This section provides the menu maps for service calibration, diagnostics and system alignment. All calibration, diagnostics or system alignment procedures must be performed by a qualified technician.
4.2
System Warm-up
The system must be warmed up to operating temperature before calibration.
1.
Ensure that the power cord is firmly attached to the system and is plugged into an appropriate outlet, then
turn on the system power.
2.
NOTE: If a System Error 2 occurs, power down, attach a wrist grounding strap, remove the cover, check the optics
assembly cable connections, and make sure the shunt is removed. Also ensure that the proper shims have
been installed. If the System Error 2 continues, contact ECRM Customer Service.
4.3
Calibration Menu
The Calibration menu (see Figure 4-1) allows service technicians to calibrate the Image Centering, Pel Correction
and Line Correction. To enter the Calibration Menu, from the Online or Offline window, press and hold the PREV
Key and then press the Menu Key. The Calibration Menu appears. Refer to the Calibration Menu Map (Figure 4-1)
for the following procedures.
When you enter values with the keypad, PREV and NEXT move the cursor left and right respectively, and SELECT
changes the value of a selected field.
NOTE: All values on the display screen appear in hundredths of a millimeter (.01mm), so that you can enter values
as whole integers without adding a decimal place. For example, a value of 27.35mm appears as 2735 on
the display.
AG11902 Rev. 5
75
Calibration Menu
ONLINE/OFFLINE
PREV
IMAGE CENTERING
SHIFT RIGHT
SELECT
IMAGE CENTERING
SHIFT LEFT
NEXT
NEXT
IMAGE CENTERING
VALUE IN 0.01 mm
IMAGE CENTERING
VALUE IN 0.01 mm
SHIFT RIGHT
BY (0-762):####
SHIFT LEFT
BY (0-762):####
NEXT
NEXT
PEL CORRECTION
VALUE IN 0.01mm
WINDOWS
NEXT
ACTUAL VALUE
#####
NEXT
LINE CORRECTION
VALUE IN 0.01mm
NEXT
EXPECTED VALUE
(see table)
Mako 36xx
Mako 46xx
762
762
..
35000
*
..
45000
*
YES/NO
YES/NO
4064
4064
.
45000
*
..
60000
*
YES/NO
YES/NO
*Actual values are calculated from the measured values when running test patterns.
NEXT
ACTUAL VALUE
#####
NEXT
IGNORE SYSTEM ERRORS?
NO
SELECT
NEXT
NEXT
/BEAMON PATH?
COAXIAL CABLE P1
SELECT
/BEAMON PATH?
RIBBON CABLE P4
NEXT
NEXT
LASER BIAS Level
% (0-100): 100
NEXT
SAVE CALIBRATION SETUP?
NO
NEXT
SELECT
ONLINE/OFFLINE
76
AG11902 Rev. 5
Press the SELECT key to start test pattern #4. The system should display Recording
Image.
2.
3.
4.
If the test pattern is cut off on the left or right side of the output, make an initial centering
adjustment as described below and output the test pattern again (make all measurements in
millimeters):
a. Calculate: X = ((Film Width - Expected grid width)/2) * 100
b.
c.
d.
e.
*Example values:
Existing margin
Emulsion Up
Trailing Edge
NOTE: For a Mako 36 the film width is usually 355mm, and the grid width is usually 350mm. For a Mako 46 the
film width is usually 460mm, and the grid width is usually 450mm.
AG11902 Rev. 5
77
This initial adjustment results in an image that appears entirely on the film and requires a
minimal adjustment to become perfectly centered. When the entire test pattern appears
between the left and right sides of the output, complete the following steps to center the
image.
5.
Measure the distance between the left edge of the film and the left edge of the test pattern
in millimeters.
6.
Measure the distance between the right side of the film and the right side of the test pattern in millimeters.
7.
Calculate the difference between these two values and divide by 2, then multiply by 100.
Apply any initial adjustment. This is the image centering value.
8.
Use the calibration menu map in Figure 4-1 to access the current Image Centering
value.
9.
Apply the image centering value to the current Shift Left or Shift Right value, as
required to center the grid on the film. For Example, if Shift Left is selected and the
image is too far to the left, subtract from the Shift Left value. If Shift Right is selected
and the image is too far to the left, add to the Shift Right value.
Smaller distance
Greater distance
Trailing edge,
emulsion side up
78
10.
Save the calibration setup as described on the menu map in Figure 4-1.
11.
Output the test pattern and measure the image centering value again. If the new image
centering value is greater than 1.0mm, repeat this procedure and add or subtract as needed
the correction value to the existing image centering value.
AG11902 Rev. 5
2.
Calculate the error by finding the difference between the test pattern width and the expected width of the test
pattern (Figure 4-4). The Pel correction value is the measured error in millimeters, multiplied by 100.
3.
Apply the pel correction value to the current Pel Correction ACTUAL VALUE.
If the grid is too narrow, subtract the pel correction value from the ACTUAL VALUE. If the grid is too
wide, add the pel correction value to the ACTUAL VALUE.
Pel Correction
ACTUAL VALUE
Figure 4-4 Pel Correction
AG11902 Rev. 5
79
Press the SELECT key to run test pattern 4. Wait until the test pattern is complete and the display no longer
indicates RECORDING IMAGE.
2.
Calculate the error by finding the difference between the test pattern length and the expected length of the
test pattern (Figure 4-5). The line correction value is the measured error in millimeters, multiplied by 100.
3.
Apply the line correction value to the current Line Correction ACTUAL VALUE.
If the grid is shorter than the expected value, subtract the line correction value from the ACTUAL
VALUE. If the grid is longer than the expected value, add the line correction value to the ACTUAL
VALUE.
Line Correction
ACTUAL VALUE
80
AG11902 Rev. 5
4.3.4 Perpendicularity
Optics shims are used to adjust the perpendicularity.
1.
Emulsion up!
Emulsion up!
trailer
shim NON power supply side
Lay the film out with the emulsion up and the trailer toward you.
3.
4.
Find the difference between the two measurements (long diagonal - short diagonal).
5.
If the measurement is greater than 0.19mm use shims to raise the side of the optics, as shown in Figure 4-6
and as explained in Section 4.3.4.2.
AG11902 Rev. 5
81
2.
Use a 9/64 allen wrench (T-handle) to loosen the four screws on the optical bed plate, which secure the
optics assembly to the rail bracket of the imagesetter. Do not remove.
3.
Place the shim(s) between the pin of the optics assembly and the optics channel
Pin
Pin
Possible
Shim Location
Possible
Shim Location
2 Mounting Screws
2 Mounting Screws
82
4.
5.
6.
Output test pattern 4 again and recalculate the perpendicularity value. If the new perpendicularity value is
greater than .19mm, repeat this procedure.
AG11902 Rev. 5
Press and hold PREV and press MENU to access the Calibration menu.
2.
3.
Press and hold PREV and press MENU to access the Calibration menu.
2.
3.
Press SELECT to choose the correct /BEAMON cable selection for the system.
2.
Cut and process the image and check it for background fog. Background fog is a change in density between
the white area on the header before the exposure sweep and the area to the left of the exposure sweep.
3.
4.
a.
Hold down PREV and press Menu to access the Calibration menu.
b.
Press PREV. The Laser Bias Level window appears. On Mako systems you can also access the Laser
Bias Level window with the System Setup menu, as described in the systems Operator Guide.
c.
Make the numerical selection as explained in 4.3 Calibration Menu on page 4 - 75. The amount of
adjustment necessary depends on the media type being used.
Repeat these steps until the exposure sweep appears without background fog.
NOTE: Reduce the bias only enough to eliminate the background fog. Overadjusting the bias may result in the loss
of vertical line width.
5.
AG11902 Rev. 5
83
4.4
Diagnostics
To access the Diagnostics menu from the ONLINE/OFFLINE prompt Press
MENU to access the Menu Options User Setup. Press SELECT to access the
Menu Options System Setup. Keep pressing SELECT until Menu Options
Diagnostics appears.
MENU OPTIONS
DIAGNOSTICS
NEXT
DIAGNOSTICS
UNWIND FILM
STOP
SELECT
NEXT
DIAGNOSTICS
SPINNER TEST
SELECT
SELECT
DIAGNOSTICS
PARK CUTTER
NEXT
NEXT
Advance
Pressed
ABOUT 5 SECONDS
SELECT
ADVANCING MEDIA
UNWIND FILM
EPROM VERSION
JAxxxx x.x.x
AVERAGING
Advance
Released
NEXT
EPROM VERSION
JAxxxx x.x.x
HIT ADVANCE TO
UNWIND FILM
DIAGNOSTICS
EPROM VERSION
ABOUT 40 SECONDS
ABOUT 5 SECONDS
AVERAGE VALUE =
######
NEXT
MINIMUM VALUE =
######
NEXT
MAXIMUM VALUE =
######
NEXT
VARIANCE TESTING
HIT STOP TO END
STOP
MINIMUM VALUE =
######
NEXT
MAXIMUM VALUE =
######
NEXT
VARIANCE = 0
#
NEXT
SELECT
SELECT TO REDO
STOP TO FINISH
STOP
*
*Variance increments from 0 to
11 as NEXT is pressed. After
Variance=4, # should always = 0.
ONLINE/OFFLINE
NO CASSETTE
84
AG11902 Rev. 5
4.4.1 Spinner Test (3600/4600 and 3625/4625 Systems (AKA Mako 36/46)
This test runs the Spinner Motor while counting clock pulses from each Start Of Line (SOL) signal to the next SOL
signal. A running average of clock pulses is maintained and variations from this average are stored in counting locations in memory called bins. Each bin keeps a tally of how many variations from the average clock pulse count
occurred during the approximately 40 second test. There are eleven bins corresponding to variations from the average
of 0 (right on the average) to 11 (11 counts and higher above or below the average clock pulse count). If there were 5
occurrences of clock pulse counts that were 3 counts above or below the average, then bin 3 would contain a total of
5. During the test, the bin containing the tally of clock pulse counts that were 3 counts above or below the average is
reported as VARIANCE=3 0005 (the number of occurrences).
NOTES:
1) The spinner test is a diagnostic tool that is used to verify the existence of a faulty spinner motor. It cannot be used to prove the quality of a good spinner motor.
2) Start-Of-Line signal must be within specifications prior to running this test.
3) This test is done for spinner motor speed fluctuation (jitter) only.
The following diagnostic aids the service technician in determining whether the average speed fluctuation of the
Spinner motor is within the range for acceptable output. This procedure must be performed by a qualified technician.
NOTE: This test is done for spinner motor speed fluctuation (jitter) only.
1.
To access the DIAGNOSTICS MENU from the ONLINE?OFFLINE window perform the following steps:
Press Menu. Press SELECT until Menu Options Diagnostics appears. Press NEXT. Press SELECT until
Diagnostics Spinner Test appears.
2.
Press NEXT. The PRESS SELECT TO START AVERAGING window will appear. Press SELECT again.
The AVERAGING window will appear. Wait a minimum of 15 minutes for the spinner motor to warm up.
Press the NEXT Key to start averaging the spinner. Approximately 40 seconds after you press NEXT, an
average will be displayed. (for example: AVERAGE VALUE=182670). This number represents the averageperiod of a revolution (of the spinner) computed over a number of revolutions. When you press NEXT, the
MINIMUM VALUE=nnnnn is displayed. Press NEXT again and the MAXIMUM VALUE=nnnnn is displayed. The differences between the average and the minimum and the average and the maximum should be
+ 6.
3.
Press NEXT again. VARIANCE TESTING STOP TO END window will be displayed. Press Stop. The
MAXIMUM VALUE will be displayed, then press NEXT and the MINIMUM VALUE will be displayed.
Then press NEXT.
4.
Variance=0
####
will appear. Each time you press NEXT, the Variance will increase by 1.
Variance=1
####
Variance=2
####
up to ...
Variance>=11
####
The variance refers to speed variations of the spinner motor. Once the VARIANCE=7 window appears, the
number displayed should be 0. Press NEXT. The SELECT TO REDO AND STOP TO FINISH window is
displayed. Press SELECT to redo. From this point on, every time you press NEXT, the number displayed
should be 0. Press NEXT to STOP the Spinner Motor test. Run this test 4 more times, each time exiting the
SPINNER TEST menu.
AG11902 Rev. 5
85
NOTE: Failure to exit the test properly or using the REDO feature may cause erroneous results.
If numbers appear after VARIANCE=7 or above during the testing on any one of the 5 times that the Spinner Motor
test was run, this is not a problem, however if more than 1 Spinner Motor test shows Variance=7 or above, then contact Customer Service.
To verify this, cycle machine power and repeat test. If jitter is no longer present, the spinner controller board may be
bad.
NOTE: Test Pattern #4 (Figure 4-9) should be used to determine jitter acceptability.
Run output with Test Pattern #4. The grid should meet the acceptance criteria. If unacceptable jitter appears
on the SOL side of the grid, the Spinner motor may need to be replaced.
.075mm
Test Pattern #4
.05mm
Trailer
86
AG11902 Rev. 5
1.
To access the DIAGNOSTICS MENU from the ONLINE?OFFLINE window perform the following steps:
Press Menu. Press SELECT until Menu Options Diagnostics appears. Press NEXT. Press SELECT until
Diagnostics Spinner Test appears.
2.
Press NEXT. The PRESS SELECT TO START AVERAGING window will appear. Press SELECT again.
The AVERAGING window will appear. Wait a minimum of 15 minutes for the spinner motor to warm up.
Press the NEXT Key to start averaging the spinner. Approximately 40 seconds after you press NEXT, an
average will be displayed. (for example: AVERAGE VALUE=182670). This number represents the averageperiod of a revolution (of the spinner) computed over a number of revolutions. When you press NEXT, the
MINIMUM VALUE=nnnnn is displayed. Press NEXT again and the MAXIMUM VALUE=nnnnn is displayed. The differences between the average and the minimum and the average and the maximum should be
+ 1.
3.
Press NEXT again. VARIANCE TESTING STOP TO END window will be displayed. Press Stop. The
MAXIMUM VALUE will be displayed, then press NEXT and the MINIMUM VALUE will be displayed.
Then press NEXT.
4.
Variance=0
####
will appear. Each time you press NEXT, the Variance will increase by 1.
Variance=1
####
Variance=2
####
up to ...
Variance>=11
####
The variance refers to speed variations of the spinner motor. Once the VARIANCE=2 window appears, the
number displayed should be 0. Press NEXT. The SELECT TO REDO AND STOP TO FINISH window is
displayed. Press SELECT to redo. From this point on, every time you press NEXT, the number displayed
should be 0. Press NEXT to STOP the Spinner Motor test. Run this test 4 more times, each time exiting the
SPINNER TEST menu.
NOTE: Failure to exit the test properly or using the REDO feature may cause erroneous results.
If numbers appear after VARIANCE=2 or above during the testing on any one of the 5 times that the Spinner Motor
test was run, this is not a problem, however if more than 1 Spinner Motor test shows VARIANCE=2 or above, then
contact Customer Service.
To verify this, cycle machine power and repeat test. If jitter is no longer present, the spinner controller board may be
bad.
NOTE: Test Pattern #4 (Figure 4-9) should be used to determine jitter acceptability.
Run output with Test Pattern #4. The grid should meet the acceptance criteria. If unacceptable jitter appears
on the Start Of Line side of the grid, the Spinner motor may need to be replaced.
Press the Menu Button. Select Menu Options USER SETUP. Then Press NEXT. The Interface mode window
appears. Press SELECT until INTERFACE MODE TEST PATTERNS appears.
AG11902 Rev. 5
87
2.
Press NEXT then SELECT to access the Test Patterns 0, 1, 2, 3 and 4. Choose the desired Test Pattern:
NOTE: If you run the Test Patterns with OVERSCAN on, the grid pattern may show a line down the side at the
beginning of the image.
Pattern #0 outputs the following:
A repeating 1 line pattern of white/black in successive 1/4th image widths. (This pattern does not start the
film drive motor.)
Pattern #1 outputs the following:
A repeating 2 line pattern with:
line 1 - the first 2/3rds black, then the last 1/3rd a pattern of four pels on/four pels off.
line 2 - the first 2/3rds white, then the last 1/3rd a pattern of four pels on/four pels off.
Pattern #2 outputs the following:
A repeating pattern which gives a series of black or white horizontal bars across 3/4ths of the line. The last
1/4th of each bar is a 50% checkerboard with a square dot dimension of 8 pels. Each horizontal bar is
repeated for 1/2 inch.
Pattern #3 outputs the following:
A 50% square dot (checkerboard) patterns. The dot's dimension is:
8 pels/lines for resolution <1016 dpi.
16 pels/lines for resolutions, 1016 <= pel resolution <=1800dpi. 32 pels/lines for resolutions, 1800
<= pel resolution <=2540dpi.
Pattern #4 outputs the following:
This generates a grid that can be used to size the machine. The test pattern is run at 2540dpi with Overscan
on, widest media width possible. It generates 25mm x 25mm grid covering an area that is model specific:
Mako 36xx = 350mm x 350mm
Mako 46xx = 450mm x 450mm
Grid size is firmware dependent.
To generate a Test Pattern, perform the following:
88
1.
2.
Press the NEXT Button. The Exposure window will appear. Press Stop. SAVE SETUP will appear. Select
SAVE SETUP YES. Press NEXT. The OFFLINE window will appear. Press the SELECT button. The Test
Pattern will start. For Test Pattern 4, the test Pattern continues to run until it stops automatically. All the
other Test Patterns run until you press the Stop Button.
3.
4.
AG11902 Rev. 5
4.5
System Alignment
The Laser Alignment option (Figure 4-10) is used to test the exposure values (0-255) for the laser. The BELT
ALIGNMENT option is used to keep the motor running while adjusting the belt. After the adjustment has been made,
the motor can be shut off.
ONLINE/OFFLINE
SYSTEM ALIGNMENT
LASER ALIGNMENT
SELECT
SYSTEM ALIGNMENT
BELT ALIGNMENT
NEXT
NEXT
EXPOSURE
VALUE (0-255)
HIT ADVANCE TO
START FILM
STOP
ADVANCE
ADVANCING MEDIA
FILM COUNT: XXX
STOP
STOP
ONLINE/OFFLINE
From the ONLINE/OFFLINE window, press and hold the PREV Key, press and hold the NEXT key, then
press the Menu key. The System Alignment menu is displayed.
2.
Press the NEXT key. The Exposure Value (0-255) ### window is displayed. Set the Exposure Value to 255.
Press NEXT until the cursor wraps around under the left most position to ensure the exposure is set (e.g.
255).
3.
With a Digital Volt Meter, measure TP5 on the Laser Driver board. If the voltage is above 10VDC, the diode
needs to be replaced. Refer to Section 6 for optics assembly replacement.
4.
Press the Stop key. You will be returned to the ONLINE/OFFLINE window.
AG11902 Rev. 5
89
90
1.
From the ONLINE/OFFLINE window, press and hold the PREV key, press and hold the NEXT key, then
press the Menu key. SYSTEM ALIGNMENT LASER ALIGNMENT is displayed.
2.
Press the SELECT key. The SYSTEM ALIGNMENT BELT ALIGNMENT window appears. Press NEXT.
Hit Advance to Start Film window is displayed. Press the ADVANCE button to start the motor. Adjust the
belt.
3.
When the adjustment is complete. Press the Stop key twice. The motor will shut off. You will be returned to
the ONLINE/OFFLINE window.
AG11902 Rev. 5
A
AC24657 .. 32, 42
accuracy .. 12
adjusting SOL .. 57
air quality .. 8
alignment, belt .. 90
alignment, laser .. 89
antistatic bag .. 34, 52
AP9981 board .. 65
assembly, cutter .. 56
B
BEAMON cable .. 32, 42
belt alignment .. 90
belt tension gage AX0065 .. 53
belt tension gage AX0073 .. 53
belt, standard .. 55
block diagrams .. 19
board control panel, AP9981 .. 65
C
cable, BEAMON .. 32, 42
calibration .. 44
Calibration menu .. 45, 75
Capstan drive .. 66
centering adjustment, initial .. 47, 77
centering, image .. 47, 77
channel readings .. 58
control panel board (AP9981) .. 65
correcting Line .. 49, 80
correcting Pel .. 48, 79
cover removal .. 38
cover sensor .. 28
customer responsibilities .. 7
cutter assembly .. 56
cutter parking .. 87
D
data, electronic .. 16
data, optical .. 16
data, physical .. 16
defect tag .. 34
defects tag .. 36, 52
Diagnostics menu .. 84
dimensions .. 16
diode shunt locations .. 38
discharge, static .. 25, 26
discharging static .. 35
display values .. 45, 75
drive encoder .. 73
drive motor .. 55
drive motor, Kapton belt .. 55
drive motor, standard belt .. 55
AG11902 Rev. 5
E
earth ground .. 9
electronic data .. 16
electrostatic warning .. 25
emulsion types .. 11
encoder, drive .. 73
English/metric .. 45
environmental requirements .. 8
EPROM replacement .. 71
Error Two .. 44, 75
F
film unwinding .. 87
firmware version .. 33, 43
floor requirements .. 8
G
gage, belt tension AX0065 .. 53
gage, belt tension AX0073 .. 53
gas shock .. 27
grid, test pattern four .. 45
ground .. 9
grounding .. 25, 26, 35
grounding strap .. 35
H
heat dissipation .. 8
I
Ignore System Errors .. 83
image centering .. 47, 77
image, test .. 51
infrared media .. 11
initial centering adjustment .. 47, 77
installation .. 7, 9
installing shims .. 51, 82
interface specification .. 18
interlock description .. 22
J
jitter .. 85, 86
K
Kapton belt drive motor .. 55
91
laser alignment .. 89
laser diode .. 38
laser diode damage .. 35, 37
laser driver block diagram .. 20
lighting .. 8
Line correction .. 49, 80
locating pins .. 32, 42
lotion .. 36
recording performance .. 12
regulations, safety .. 17
release lever .. 7
removing the cover .. 38
removing the optics .. 29, 39
replacing the spinner motor .. 30, 40
return optics .. 34, 52
RMA number .. 34, 52
machine features .. 10
main control board block diagram .. 21
maintenance procedures .. 25
Mako specifications .. 10
material, packing .. 36
measuring values .. 45, 75
media types .. 11
menu, Calibration .. 45, 75
metric units .. 45
moisturizing lotion .. 36
motor, drive .. 55
motor, spinner .. 85, 86
motor, standard belt .. 55
safety regulations .. 17
sample output .. 34, 52
sensor, cover .. 28
shim placement .. 32, 42, 51, 82
shims .. 50, 81
shock, gas .. 27
shunt locations .. 26, 38
shunt removal .. 27
site preparation .. 7
SOL adjustment .. 57
specifications, interface .. 18
specifications, Mako .. 10
spinner motor .. 85, 86
spinner motor replacement .. 30, 40
spinner test (standard) .. 85, 86
standard belt drive motor .. 55
Start of Line adjustment .. 57
startup temperature .. 9
static bag .. 36
static wrist strap .. 25, 26, 35
system alignment .. 89
system block diagrams .. 19
System Error Two .. 44, 75
system power .. 8
system warmup .. 44, 75
O
offline test patterns .. 87
operating temperature .. 9
optical data .. 16
Optics Defect tag .. 34
optics defect tag .. 52
optics removal .. 29, 39
optics returns .. 34, 52
optics temperature .. 35, 37
oscilloscope .. 57, 58
output, sample .. 34, 52
P
packing material .. 36
park cutter .. 87
patterns test .. 87
Pel correction .. 48, 79
performance .. 12
perpendicularity adjustment .. 50, 81
physical data .. 16
pinch roller .. 7
power cord types .. 9
power requirements .. 16
power supply .. 60
power supply adjustment .. 61
T
tag, defects .. 36, 52
tag, Optics Defect .. 34
temperature .. 35, 37
temperature at startup .. 9
temperature for operating .. 9
tension gage, belt AX0065 .. 53
tension gage, belt AX0073 .. 53
test image .. 51
test pattern # four .. 45
Test Pattern 0 (zero) .. 58
test patterns, offline .. 87
U
units of measurement .. 45
unwind film .. 87
92
AG11902 Rev. 5
utility requirements .. 16
V
values, measuring .. 45, 75
version, firmware .. 33, 43
vibration .. 8
visible media .. 11
voltage specifications .. 61
W
warmup, system .. 44, 75
wrist grounding strap .. 25, 26, 35
wrist grounding strap connections .. 26, 38
AG11902 Rev. 5
93
94
AG11902 Rev. 5