Section 6 - 3: List of Contents

Repair and Service
DD+DIS175.05E Troubleshooting
Section 6 - 3
List of contents
1 Troubleshooting: General ........................................................................... 2

2 Symptom: Printer does not start up properly............................................ 3
3 Symptom: An error message is displayed on the internal or external
display........................................................................................................... 4
4 Symptom: An error message as text is displayed on the internal
display........................................................................................................... 5
4.1 Symptom: "Remove output jam": Film jam or film running askew in the decurl
unit .............................................................................................................................5
5 Symptom: Drystar 3000 does not print. No error message is displayed. 9
6 Symptoms: Image fault...............................................................................11
6.1 Contrast and density reproduction faults ............................................................11
6.1.1 Dmin too high ...........................................................................................................12
6.1.2 Dmax too high or too low..........................................................................................12
6.1.3 Density reproduction / Optimal perceivable not okay ...............................................14
6.1.4 Contouring visible; 'Landscaping' .............................................................................16
6.2 Line artifacts in transport direction ......................................................................17
6.2.1 Dust stripes...............................................................................................................17
6.2.2 Line artifacts < 1mm .................................................................................................21
6.2.3 Line artifacts > 1mm .................................................................................................24
6.2.4 Wide bands with lower density at the left and/or right hand side of the film .............31
6.3 Line artifacts vertical to the transport direction..................................................33
6.4 Line artifacts diagonal to the transport direction................................................35
6.5 Point artifacts..........................................................................................................36
6.5.1 Pinholes....................................................................................................................36
6.5.2 Bubbles.....................................................................................................................37
6.5.3 Dust particles on the printdrum.................................................................................38
6.5.4 Dust particles in the film ...........................................................................................39
6.6 Surface artifacts .....................................................................................................40
6.7 Position of the image on the film not centered ...................................................41
7 Symptom: Hard disk doesn’t work ............................................................43
7.1 Software Installation / Configuration from Scratch.............................................43
7.1.1 Software Installation from Scratch............................................................................43
7.1.2 Configuration from Scratch.......................................................................................43
8 Troubleshooting Ethernet failures.............................................................44
9 Bus error......................................................................................................45
9.1 Bus crash caused by COS board..........................................................................45
Printed copies of this document are not controlled.

The reader should always refer to MedNet to ensure that they are working with the latest copy of the document.
Revision 40 Type 5361 Section 6.3 / I
2005-07-20 Agfa Company Confidential
Repair and Service
Troubleshooting DD+DIS175.05E
1 Troubleshooting: General
In case of troubles with the Drystar3000 we can distinguish between different symptoms.
Enclosed a list of typical symptoms that may occur
# Symptom Description Reason Refer to

1 Printer does not start up. Either nothing on the AOS shell not booted up 2
internal display or "Drystar 3000 initialisation, completely
please wait" forever (> 5 min.)
2 An error message is displayed on the internal or Problem during printer 3

external display operation: Printer SW / HW
problem.
3 An error message as text is displayed on the Problem during printer 4

internal display operation:
A user intervention is
?
ERROR Remove required.
536163XX.CDR
Output Jam
4 Drystar 3000 does not print. No error message is Either the image does not 5
displayed. get to the printer (network)
or printer configuration
mismatch
5 Image fault: Monitor at console and image Either problem of image 6

printed at Drystar3000 are different processing (Software /
Hardware) or problem of
the host system

Section 6.3 /2 Drystar 3000 (Type 5361) Revision 40
Agfa Company Confidential 2005-07-20
Repair and Service
2 Symptom: Printer does not start up properly

Either nothing on the internal display or
"Drystar 3000 initialisation, please wait"
forever (> 5 min.)
Reason:
AOS shell not booted up completely
Cure:
• Start IMOS Drystar3000 (If you do not get access to the Drystar 3000, the hard disk may be
defective. See section 7: Symptom: Hard disk doesn’t work
• Enter Menu „Application - Customization - Name/Value Edit“
• Look to the complete list:
• The list of different components stops somewhere before CMNXXX21 (see example)
In this example, the MFRI driver is the last one that booted up completely. Most likely the
MFRI is not jumpered correctly or a configuration mismatch exists.
⇒ General Proceeding in such a case: Check whether the VME hardware interfaces are
really installed as shown in the configuration screen. Check jumpersetting of the VME
interface.
⇒ In case the problem is originated from SW problems during SW installation or
configuration, a configuration from scratch is recommended (see section 7.1.2).

Revision 40 Type 5361 Section 6.3 / 3
Repair and Service
Note: If the NVE list stops with ARTXXX00, the reason is either, that the system is halted
(make a reset in this case) or that a VME bus crash occurred. See also section 9, Bus
error.
3 Symptom: An error message is displayed on the internal or external display
Reason:
Problem during printer operation: Printer SW / HW problem.
Cure:
• Start IMOS Drystar3000
• Select „Repair - Error Messages“ and enter the fault to get an explanation.
Note: Error messages are always created according to the "father-son" principle. I.e. there is
always a basic error creating another one and so on.
How to see the current error messages:
• They are either displayed on the local keypad or the LCD user keypad. If errors are
displayed as text, select menu 10 on the local keypad: Print Engine - Error Details to view
the corresponding error code.
Additionally, the error messages are logged in the logbook:
• Select "Logbook" in the main menu "Repair" in IMOS.
• Select „detailed“ to get the explanation of the errors, too.
Attention: Always look to the error chain. If it ends with „0000“ the error was repaired
internally.
How to get the explanation to error messages:
• Select „Error messages“ in the IMOS Drystar 3000 main menu „Repair“.

Repair and Service
4 Symptom: An error message as text is displayed on the internal display
?
ERROR Remove
536163XX.CDR
Output Jam
Reason:
Problem during printer operation: A user intervention is required.
Cure:
• First perform the action as required on the internal display (e.g. remove filmjam)
• Then select menu 10 on the local keypad „Print Engine“ - „Error Details“. Two errors will be
displayed.*
• Select „Repair“ - „Error Messages“ and enter the two faults to get an explanation. Normally
the first error message points to the problem.
• In case the problem persists after resetting the device and the following filmrun,
troubleshoot as described in the error explanation.
4.1 Symptom: "Remove output jam": Film jam or film running askew in the decurl unit
Symptom: Film runs askew through the decurl unit

or
Display "remove output jam" in combination with the error message "6C4E6
or 6C4BF" (see local keypad, menu 10, print engine - error details)
Reason 1: Loose screws or several screws missing on the decurl roller flange, (see
Figure 1 and Figure 2)
- Due to the missing screws the flange may shift and then the rollers are no
longer parallel to the film transport level.
This happens mainly in machines manufactured prior to October 1998.
Cure 1: Check, if the screws are fully tightened and if they are complete
The screws are visible after removal of the decurl heat protection cover and the
corresponding decurl side panels.
- If the screws have not been fully tightened:
• Tighten the screws:
On the left-hand side of the decurl unit the wiring of the heater must be
removed as well.
• Replace the decurl unit at the next occasion.
- If one or more screws are missing:

• Replace the decurl unit.

Repair and Service
Figure 1: left hand view (without decurl Figure 2: right hand view (without
top and side cover) decurl top and side cover)
The causes an remedies described here refer to the decurl unit with part
number CM+309911.1
The decurl unit CM+309913.0 has been introduced in year 2001 as a remedy in the
series production. (to be recognized at sticker "A309913.0")
Reason 2: Transport roller shaft of the film take over no longer parallel.
- If the shaft is not parallel, the film may enter the decurl unit at an angle or
even fail to reach the decurl unit.
This may be the result of e.g. to much force on the opened film take over
unit.
Cure 2: Check, if the film take over unit transports the film straight (parallel).
- Roller pressure on the film must be uniform,
• insert a film in the film take over

unit.
• Close the film take-over unit.
• Lift the shaft slightly on the drive

side of the horizontal film
alignment.

Repair and Service
• Check the pressure on the film on

both rollers.
- In case of pressure differences:

• align the shaft in parallel,
or
• replace the film take over unit.
Symptom: Film runs askew through the decurl unit

or
Display "remove output jam" in combination with the error message "6C4C0"
(see local keypad, menu 10, print engine - error details)
Reason: Twisting of one of the bearing blocks for the decurl rollers.
- This may happen on each side, right or left, when a film has been pulled out
of the decurl unit with excessive force.
The last decurl roller is then no longer parallel – the film runs askew.
Cure: Correct positioning of the bearing block.
• Lift the shaft by means of a screwdriver, as shown in Fig. (see arrow "lift
axle"), and turn the bearing block back to its correct position, either
manually or with a screwdriver.

Repair and Service
bearing
Okay Not Okay
Figure 3
Or
• If this is not a permanent solution for the problem:

replace the decurl unit by the latest revison of the decurl unit.

Repair and Service
5 Symptom: Drystar 3000 does not print. No error message is displayed.
Reason:
Either the image does not get to the printer (network problem) or printer configuration
mismatch
Cure:
• Enter Menu „Application - Customization - Name/Value Edit“
• Look to the drivers with extension „11“: The list of these components should look like
displayed here
• In case it does not look like that, reconfigure the output of the printer as Drystar 3000.
Select „force pin“ in the configuration screen.
• In case the drivers for the print engine are okay, have a closer look to the drivers for
networking:
Note: In the example below only the driver for APIP has been loaded. If the Drystar 3000 is
connected to a host modality via DICOM, lp, pap or ftp, different drivers may be loaded.

Repair and Service
Network Protocol Drivers

APIP CMNXXX21
ETHXXX21
DICOM CMNXXX22 (or higher)
PMSXXX22 (or higher)
FTP CMNXXX?? (?? > 21)
LP CMNXXX?? (?? > 21)
PAP CMNXXX?? (?? > 21)
PAPXXX?? (?? > 21)
For further information see section 8 „Troubleshooting Ethernet failures“
• In case the driver is not installed, use the proper network configurator to reconfigure the
network connection:
- IMOS Megacon for APIP connection
- IMOS DCM for DICOM connection
- IMOS MPS for postscript connection

Repair and Service
6 Symptom: Image faults
The list of artifacts on the film is divided in following types of artifacts:
# Artifact Example Refer to

1. Contrast and density Dmax 2.7 instead of 6.1
reproduction faults 3.0 O.D.
2. Line artifacts in transport Bright lines in transport direction 6.2
direction
3. Line artifacts vertical to the 'Banding' vertical to transport direction 6.3
transport direction (parallel to print drum)
4. Line artifacts diagonal to the Moiree pattern 6.4
transport direction
5. Point artifacts Very small white dots 6.5
6. Surface artifacts Scratches 6.6
7. Position of the image on the Only fits half of the image is printed 6.7
film not centered
6.1 Contrast and density reproduction faults

The customer will usually complain about
• Image overall too dark
• Image overall too bright
• On the monitor the image looks better than on the film. Refer to remark below.
• Image not sharp enough
Enclosed a table which divides the symptoms mentioned above in 5 different symptoms:
# Artifact Refer to
1. Dmin too high 6.1.1
2. Dmax too high or too low 6.1.2
3. Optimal perceivable levels not okay 6.1.3
4. Contouring visible; 'Landscaping' 6.1.4

Repair and Service
6.1.1 Dmin too high

Symptom The minimum density on the clinical (white areas, e.g. text) and test
images (white areas, e.g. 100% field of SMPTE test pattern) is more than
0.02 density units higher than before printing.
Example:
Fog level before printing 0.20 O.D.
Fog level after printing 0.25 O.D.
This fault can best be observed in the 100% square of the SMPTE test
image
Reason • Film calibration not performed and/or
• MDM needs re-calibration
Cure (1) Perform a film calibration. Refer to chapter 6.6

(2) Print the image SMPTE.tif and measure the 100% square
(3) If Dmin is still not OK, perform an MDM calibration followed by a film
calibration. Refer to chapter 6.6.
6.1.2 Dmax too high or too low

Symptom The maximum density on the clinical (black areas, e.g. frame around the
image) and test images (black areas, e.g. 0% field of SMPTE test pattern)
is more than 0.1 density units lower or higher than the target Dmax
(= Blue based film 3.1 O.D / Clear based film 2.95 O.D.).
Refer to note below regarding density measurement.
Example:
Dmax = 2.7 O.D.
This fault can best be observed in the 0% square of the SMPTE test
image

Repair and Service
Density measurement of Drystar films:

• For density measurement of Drystar films a calibrated densitometer
MacBeth TR-924, X-Rite 331, 341, X-Rite 301, X-Rite 310 or
Gretag D200-2 is required.
• The reference densitometer for Drystar 3000 is the MacBeth TR-
924 densitometer. The aperture of the spot is 3 mm and a visual
filter must be used.
• In the field the MacBeth TR-924 is not available. Normally, other
densitometers can only be used provided that an approved
recalculation table or recalculation function for the used
densitometer is available.
• Recalculation tables are available for X-Rite 331, X-Rite 341, X-Rite
310 and Gretag D200-2. Refer to MEDNET, GSO library.
• The densitometers must be calibrated with the calibration wedge of
the supplier according to the instructions of the supplier.

• MDM needs re-calibration and/or
• TPH profile needs to be calibrated

(3) If Dmax is still not OK, use another filmbatch (other emulsion
number)
(4) Perform a film calibration
(5) If Dmax is still not OK, perform an MDM calibration followed by a
film calibration. Refer to chapter 6.6
(7) If Dmax is still not OK perform a Printhead profile calibration.
Refer to chapter 6.6.
(8) Perform a film calibration.
(9) Print the image SMPTE.tif and measure the 0% square.
(10) If Dmax is still not OK, order new film with other emulsion
number.

Repair and Service
6.1.3 Density reproduction / Optimal perceivable not okay

Symptom Customer complains about 'on the monitor the image looks better than on
the film'
Testimage This fault can best be observed in the 'ktbwd2n.tif test image. Refer to
Figure 5 page 15.
Each square differs from its neighbor by 2 density value (2 of 256). Each
square has inside a small square which is 2 density units darker than the
outside square.)
• MDM needs re-calibration and/or
• TPH profile needs to be calibrated

(2) Print the image ktbwd2n.tif and check at the lightbox whether all
small squares are visible in the big squares.
(3) If not all small squares are visible, perform an MDM calibration
followed by a film calibration. Refer to chapter 6.6
(5) If still not all small squares are visible, perform a Printhead profile
calibration. Refer to chapter 6.6
(6) Perform a film calibration.
small squares are visible in the big squares. See also note next
page.
In case the customer complains about

'on the monitor the image looks better
than on the film' it is advised to check
the monitor calibration.
This can be done by loading a

SMPTE test image on the monitor,
and checking whether the 5% and
95% fields are visible.
Figure 4

Repair and Service
Figure 5: ktbwd2n.tif test image
All small squares inside the big squares are only visible in case of
• proper printer calibration
• proper viewing conditions at the lightbox.
Refer to the Hardcopy Application Manual, available in the "Harcopy -
General Hardcopy Info" section on the MEDNET GSO Library.

Repair and Service
6.1.4 Contouring visible; 'Landscaping'
Symptom
Figure 6
Gray shaded areas do not show a continuous grey shading but show
visible, hard grey steps (also called 'landscaping', i.e. it looks like contour
lines in a hiking map)
This fault can best be observed in a clinical image or the 'ktbwd2n.tif test
image. Refer to Figure 5 page 15.
Each square differs from its neighbor by 2 density value (2 of 256). Each
square has inside a small square which is 2 density units darker than the
outside square.)
Reason • Sensitometry far away from the real film characteristics; calibration
not performed and/or
• Printhead profile needs to be calibrated
Cure (1) Perform a film calibration
(3) If not all small squares are visible, perform an MDM calibration
followed by a film calibration
(5) If not all small squares are visible perform a Printhead profile
calibration

Repair and Service
6.2 Line artifacts in transport direction

Enclosed a table which divides the line artifacts in 4 different symptoms:
# Artifact Refer to
1. Dust stripes 6.2.1
2. Line artifacts < 1mm 6.2.2
3. Line artifacts > 1mm 6.2.3
4. Wide bands of lower density at the left and/or right hand side of the 6.2.4
film
6.2.1 Dust stripes
Symptom
536433SA.CDR
Figure 7
Dust stripes are most often white, sometimes dark lines, and mostly
ragged and not sharp. Are always in the transport direction, and are from
a few cms long up to the total length of the film.
This fault can best be observed in the flat3001.bla test image.
Reason 1 Dust on the film. The dust particle stays on the thermal head for a
certain time. This leads to less heat on the film as long as the dust
particle stays between the thermal head and the film.
Cure 1 Normally okay after next film, otherwise clean the thermal head.
For cleaning instructions refer to section 6.2.1.1, page 21

Repair and Service
6.2.1.1 Check of Film for Dust Stripes and/or Scratches
o TH screw driver
o Ink eraser
o Service PC with IMOS Drystar 3000
(1) In IMOS Drystar 3000 select
Repair
PrintEngine
Print Testpage
flat3001.bla
to print a flatfield with 1.0 O.D.
(2) Check the "flat3001.bla" test image for dust stripes and scratches.
- If dust stripes and/or scratches are visible follow the TH cleaning
procedure as described in Figure 8: TH cleaning procedure.
Basic Rules for the TH Cleaning Procedure

• Use the correct cleaning material.
1. Wet cleaning: Use a lint free cloth lightly moistened with Isopropyl -
alcohol or a cleaning tissue.
2. Dry cleaning: Use the blue side of an ink eraser. Make a linear
cleaning movement, parallel to the resistor line. Refer to Figure 9.
3. For the last wet cleaning action observe the rule: The last cleaning
action must be carried out in one way!
• For the Isopropyl alcohol observe the rule: As less water is in the alcohol
as better. Water can damage the TH. We recommend using a 90%
Isopropyl alcohol.

Repair and Service
TH cleaning
Dry TH cleaning
procedure
procedure
Print flat3001.bla*and
**medical.tif test image
Dismount TH
vertical stripes No Clean TH with

Okay Isopropyl alcohol
visible ?
(”wet” cleaning)
Yes or in doubt
Use ink eraser
Clean TH with for cleaning.
Isopropyl alcohol Refer to figure next page.
Clean TH with
Print flat3001.bla *
Isopropyl alcohol
test image
additional Mount TH
Yes
vertical stripes
visible ?
Clean TH with
No Isopropyl alcohol
Previous Stripes No
Okay
still visible ?
Print flat3001.bla*test image
Yes
Perform Dry TH
Cleaning Procedure
New vertical Yes
536363mm.cdr stripes visible ?
No
Vertical No
stripes visible ? Okay
Yes
Perform TH ***
* Local keypad: Print Diskette - Image Selection - medical.tif profile calibration.
** In IMOS select: Repair - PrintEngine - Print Testpage - flat3001.bla

Stripes visible in No
medical_image test Okay
*** In IMOS select: Repair - PrintEngine - Modules -
MDM Calibration - Calibrate TH - Profile image ?
Yes
Observe TH cleaning rules
described next page Replace TH
Figure 8: TH cleaning procedure

Repair and Service
• Before dry cleaning with an ink eraser to remove print stripes dismount
the thermal head: The Drystar 3000 is quite dust sensitive.
• During cleaning do not push on the IC cover of the Thermal Head.
• The Thermal Head has a printed circuit board integrated. This means, that
the same ESD (electromagnetic discharge) guidelines apply for the
Thermal Head than for printed circuit boards.
• The aluminum surface, on which the Thermal Head is mounted, may not
be scratched during dismounting of the Thermal Head. Possible scratches
have to be removed with a sand paper or a file, to prevent uneven
pressure of the Thermal Head on the film.
• When replacing or cleaning the Thermal Head take care not to damage
the Thermal Head: Too high pressure on the TH film guide can lead to
the failure of single heating elements. Be aware, that the Thermal Head
is a very sensitive part and has to be treated very cautiously
TH resistor line
TH cross section
TH top view
Blue side
Ink eraser
e.g. Pelican
type BR40 536410cd.cdr
linear cleaning movement

parallel to TH resistor line
Figure 9: Usage of ink eraser for TH cleaning
Instruct the customer, not to fill the input tray with dropped films or films
coming from jam clearances:
• These re-inserted films can be contaminated with dust and fingerprints
which can result in image artifacts or a defective thermal head.
• If the film is inserted the wrong way, the thermal head gets heavily
contaminated, what makes a service intervention necessary.

Repair and Service
6.2.2 Line artifacts < 1mm
Symptom
536433SB.CDR
Figure 10
Dark line(s) in print direction.

• Width can be< 1mm (Sub mm TPH banding) or 0.05 mm (one pixel
line).
• Can be one or more lines.
• Line can be intermittent.
• Can be a combination of dark and white lines.
Reason • One or more defective resistors of the TH (sharp lines).

• Shift of the resistor values of the resistor elements (unsharp lines).
• Deposits on the TH
Cure (1) Clean the thermal head. For cleaning instructions refer to section
6.2.1.1, page 21.
(2) If this does not help exchange the thermal head.

Repair and Service
Symptom
536113AO.CDR
Figure 11
Vertical bright lines
• Thin vertical bright lines across the complete film.
Reason 1 • Software problem on the COS Board revision E.

COS board rev. E is installed in machines with SN < 2177 (except SN
2171; 2172; 2173)
Cure 1 • Installation of the Software Version ≥ 1.73.
During the software installation there is an automatic update of the
firmware of the COS Board to rev. F.
- as an alternative -
• Installation of the COS Board rev. F (EB+53610593)
Reason 2 • Hardware problem on the AIC1 Board
Cure 2 • Replacement of the AIC1 by a AIC1 Board, Rev. F (EB+53611092).

The THP1 Board previously mounted on the modified data cables is
now integrated on AIC1 Board, rev. F and is thus no longer necessary.

Repair and Service
Symptom
536433SC.CDR
Figure 12
White or bright line(s) in print direction.

• Width can be < 1mm (Sub mm TPH banding) or 0.05 mm (one
pixel line).
• Can be one or more lines.
• Line can be intermittent.
• Can be a combination of dark and white lines.
Reason • One or more defective resistors of the TH (sharp lines).

• Shift of the resistor values of the resistor elements (unsharp lines).
• Scratches
o Film moves along a sharp mechanical part inside the printer
o Contamination of the TH
Cure (1) Clean the thermal head. For cleaning instructions refer to section
6.2.1.1, page 21
(2) If the fault is still visible, check the film for scratches: Print Testfilm
„artifac2.bla“ and check whether the scratch corresponds to a
mechanical part which is printed on the film. See also section 6.6,
Surface artifacts
(3) In case the fault is still visible exchange the thermal head.

Repair and Service
6.2.3 Line artifacts > 1mm
Symptom
536433SQ.CDR
Figure 13
• Bright vertical lines over the whole film length.
• The stripes can be very small
(< 1 mm) to quite wide ( > 2 mm)
• The distance from line to line is irregular
• By keeping the film horizontally with light in the background small
scratches can be seen on the emulsion side of the film.
Reason Film backing layer deposits on the TH after printing the film on the wrong
side.
Cure Clean the thermal head For cleaning instructions refer to section 6.2.1.1,
page 21.

Repair and Service
Symptom
536433SE.CDR
Figure 14
Narrow (between 1 and 5 mm) to wide (> 5 mm) lines in print direction.
Lines can be brighter or darker. This fault is named "mm TPH banding" (1
to 5 mm) or "Macro TPH banding" (> 5 mm)
Reason • Dirt on the TH.

• Dirt on the print drum
• TH resistor drift
• TH driver defective. See also example images next page
Cure (1) Check the print drum for conatmination
(2) Clean the thermal head. For cleaning instructions refer to section
6.2.1.1, page 21.
(3) Print a flat3001.bla test image .
(4) If problem is still visible, perform a printhead calibration. Refer to
chapter 6.6, Calibrations

Repair and Service
Symptom
Figure 15
Wide, dark, regular vertical stripes. The stripes correspond to the shape of
the decurl rollers.
Note: The example, shown here, is the print of a flat3001.bla" test image.
In the clinical image the stripes are mixed with the image information. The
stripes must not necessarily be symmetric. Probably they are only visible
on one side.

To confirm the fault proceed as follows:
(1) Print Testfilm „artifac2.bla“
(2) Put the film „artifac2.bla“ on the flat3001.bla test image film
(3) Put them on the lightbox.
(4) In case the problem is really originated by the decurl-rollers, you will
see the fault-pattern on the displayed decurl rollers on the„artifac2.bla“
film.
Reason 1 Most likely dirt on the infrared sensor
Because of the dirt the temperature sensor measures a lower temperature

which then results in a higher decurl temperature.
Cure 1 Clean the IR sensor or replace the decurl unit. Refer to note below,

Repair and Service
In all machines manufactured up to mid-October 98 the decurl unit must

be replaced to replace the IR sensor, since the IR sensor is hardly
accessible (see Figure 16 ),
In machines with a separately mounted IR sensor (see Figure 17)
remove the IR sensor and clean it. Do not open the adjusting nut. These
must only be loosened for replacement of the temperature sensor.
531130a.CDR
Figure 16: Decurl unit with fixed IR Figure 17: Decurl unit with separately mounted
sensor IR sensor
Reason 2 IR sensor defective
Cure 2 Replace the IR sensor
Reason 3 PMC1 board defective
Cure 3 Replace the PMC1 board
Pollution of the Printer:

When removing the decurl unit, please consider the following points to avoid pollution
of the printer:
• Never use compressed air to remove them since this would distribute the
particles all over the machine and its surroundings.
• If there are any light particles / dust in the machine, remove them with a
vacuum cleaner.

Repair and Service
Symptom
10,16 mm
or 5,08 mm
or 2,54 mm
536163km.cdr
Figure 18
Persistent dark line in print direction. The width of the dark line is 2.54 or
5.08 or 10.16 mm.
In comparison to TPH banding (see previous symptom) the dark line is
more pronounced.
This fault is called "TH driver banding"
Reason TH driver defective
Cure Replace the Thermal Head

Repair and Service
Symptom
10,16 mm
or 5,08 mm
or 2,54 mm
536163kl.cdr
Figure 19
Persistent blank line in print direction. The width of the blank line is 2.54
or 5.08 or 10.16 mm
This fault is called "TH driver drop"

Repair and Service
Symptom
10,16 mm
or 5,08 mm
or 2,54 mm
536133SM.CDR
Figure 20
Intermittent white line in print direction. The width of the blank is 2.54 or
5.08 or 10.16 mm This fault is called "Intermittent TH driver drop"

Repair and Service
6.2.4 Wide bands with lower density at the left and/or right hand side of the film
Symptom
536433SH.CDR
Figure 21
Uneven density at the right and/or left hand side of the image. Density is
too low compared to the middle part of the image.
The reason for this fault is

• bad TPH pressure or
• aged print drum (changed elasticity of the rubber of the drum)
Indications to distinguish between bad TPH pressure and an aged print

drum:
Bad TPH pressure (refer to reason 3 below):
o the uneven density is more pronounced
o the Dmax decreases to a very low level, sometimes to zero.
o the uneven density most often shows up right after the
installation of a thermal head
Aged print drum (refer to reason 2 below)
o the Dmax decrease is less pronounced compared to bad TPH
pressure.
o uneven density related to an aged print drum will come up after
a certain number of films. With a drum life time of 100.000
prints the uneven density is probably caused by drum ageing.

Repair and Service
Reason 1 • After exchange of the print drum the Printhead profile was not
executed
Cure 1 • Perform a Printhead profile calibration.
Reason 2 • Aging of the print drum: Different elasticity of the print drum rubber
over the drum width.
Cure 2 • Perform a Printhead profile calibration.

• In case this does not help, exchange the print drum.
Reason 3 • After replacing or dismounting the TH, the pressure of the film against
the thermal print head may be uneven.
• Due to age related reduction of the spring force, the pressure of the
film against the thermal print head is uneven.
Cure 3 • Adjust the pressure of the film against the thermal head again and
use the adjustment kit with the order no. EB+53611750 TOOLKIT TO
ADJUST TH PRESSURE
Reason 4 • Heat conducting material of thermal head not homogeneous anymore
(should only happen for devices with SN<1895).
Cure 4 • Only for devices with SN<1895: Perform a Printhead profile

calibration.
• In case this does not help, exchange the TH

Repair and Service
6.3 Line artifacts vertical to the transport direction
Symptom
536433SD.CDR
Figure 22
Regular line structure 90° to print direction, also called 'banding' or

'transport shocks'. Usually only visible in areas, where the density is
constant.
Reason Irregularities in the film transport system (mechanical problem).

Depending on the distance of the banding lines, following parts can
cause such a banding:
• 128 mm distance: (= image length for 1 rotation of the flat belt):

object on flat belt; printer out of operation for a long time
(pressure marks on flat belt)
• 111 mm distance (= image length for 1 rotation of the drum):
drum error, object on flat belt pulley, drum bearings worn out.
• 17 mm distance: (= image length for 1 rotation of the toothed
belt): object on toothed belt
• 15 mm distance: (= image length for 1 rotation of the encoder
reduction gear): Worn out bearings of the encoder; contact
problem of encoder cable
• 2,6 mm (= image length for 1 rotation of the drum motor axle):
Drum drive motor bearings worn out, tension of the toothed belt
too high
• < 1 mm: Defective encoder
• Irregular distance: Bad TH data cable connection or defective TH
data cable

Repair and Service
Cure Check the complete print drum drive (motor bearings, drum, belt pulleys,
belt tension).
Cure depends on the distance of the lines.
Symptom
536163AY.CDR
Figure 23
One (or more) thin horizontal dark line in the image. Initially sporadic,
later on it might even be in every image. Eventually a bright line is visible
above the dark one.
Reason Most likely rust on the shaft assembly bushing. As this bushing is one of
3 supports of the TH in print position, it is possible, that a non-defined
support position can lead to small slipping down of the TH during
printing.
Cure Dismount the shaft assembly and grease the bushing (for instrcutions
see section 13, FSBs, DD+DIS013.99M).
Note 1: In all devices with SN > 1916 (+ additional SN1911) the bushing
is greased already.
Note 2: This greasing has to be done only once in a lifetime.

Repair and Service
6.4 Line artifacts diagonal to the transport direction
Symptom
Figure 24
Moiré pattern: Dots or lines, appearing in regular distance over the

whole film. Sporadic (intermittent contact) or most often persistent.
Appearance depends on frequency of the video signal (i.e. may differ
from one to another installation).
Reason Interrupted ground connection between the AFR2 Board rev. A and the
housing
• Possibility 1: Provide the missing ground connection between PCB
Cure
and housing by soldering a solder tag. These solder tags are
available in packages of 100 including the instructions
(EB+44022720).
• Possibility 2: Installation of the AFR2 Board, Rev C, available as
spare part. (EB+44022622).

Repair and Service
6.5 Point artifacts

Enclosed a table which divides the point artifacts in 4 different symptoms:
# Artifact Refer to
1. Pinholes 6.5.1
2. Bubbles 6.5.2
3. Dust particles on the printdrum 6.5.3
4. Dust particles in the film 6.5.4
6.5.1 Pinholes
Symptom
536163SD.CDR
Figure 25
These errors show as small transparent and isolated dots,

typically < 0.2mm.
Reason • Pinholes are present in the film before printing
Cure • Pinholes must be regarded as a film problem (which cannot be

avoided).

Repair and Service
6.5.2 Bubbles
Symptom
536163SE.CDR
Figure 26
Bubbles show up as clusters of small pinholes, usually in the Dmax
area of the film.
Bubbles must be evaluated with a magnifying glass.
Reason • Drum position (= adjustment of the eccentric drum) not optimized.
Cure (1) Perform a film calibration

(2) Print the image tpa_v1.tif and check for bubbles
(3) If the bubbles are still present perform an MDM calibration
followed by a film calibration.
(5) If the bubbles are still present, adjust the drum position according
to the procedure ‘adjustment of the eccentric drum’. Refer to
chapter 6.6, Adjustments
(8) If the bubbles are still present, use film with different emulsion
number, if possible.

Repair and Service
6.5.3 Dust particles on the printdrum
Symptom
approx. 111 mm
approx. 111 mm
approx. 111 mm
approx. 111 mm
536163SF.CDR
Figure 27
Oval or round spot with a lower (or higher) density. There is sometimes a
zone of higher density in the center of this area. The error is repeated a
few times on the film.
Distance between errors equals the drum circumference (= 111 mm)
Reason • Dust/dirt on the print drum. Drum errors are easy to detect since the
circumference of the drum is small compared to the length of the film.
This results in the same drum error a number of times on the same
printed film having a distance between errors equal to the drum
circumference (= 111 mm)
Cure (1) Print the flat3001.bla test image

(2) Clean the print drum with a cleaning tissue soaked in water
(3) Print again the flat3001.bla test image.

Repair and Service
6.5.4 Dust particles in the film
Symptom
536163SG.CDR
Figure 28
Transparent spots, usually a black particle can be seen in the middle of
the transparent spot.
Reason • Dust particles or aggregates in the top layer of the film
Cure • Dust particles in the film are a general film problem (which cannot be
avoided 100%).

Repair and Service
6.6 Surface artifacts
Symptom
536433SC.CDR
Figure 29
Scratches: Scratches appear as one or more bright line over the whole
length of the film.
To judge whether a bright line is caused by a scratch, take the film from
the light box and check the surface at both sides of the film by keeping it
horizontally with light in the background. In addition scratches can be felt
with the finger nail.
Reason • Most likely contamination of the TH

• Mechanical part inside the printer (unlikely)
Cure (1) Clean the TH. For cleaning instructions refer to section 6.2.1.1,
page 18.
(2) In case this does not improve the stripes, print the image
‘ARTIF*.BLA’ (IMOS Drystar 3000 - Repair - Print Engine - Print
Testpage)
The mechanical part which possibly causes the line artifact will be
indicated by the scratch on the film.
• In case the mechanical part which causes the scratch(es) cannot be
detected, most likely persistent deposits on the TH are the cause of
the scratches. In this case replace the TH.

Repair and Service
6.7 Position of the image on the film not centered
Symptom
Figure 30
The image information is not in parallel with the film edges
This fault can be observed in the any image.
Reason Vertical alignment incorrect: The stops in the input tray are not on the
same level.
Perform a vertical alignment procedure. refer to chapter 6.6, Adjustments.
Cure

Repair and Service
Symptom
Figure 31
The upper and the lower edge of the image information do not have the
same distance to the film edge (D1 and D2). The vertical adjustment of
the image is not correct.
This fault can be observed in the any image.

Reason Vertical alignment out of adjustment: The stops in the input tray are too
high or too low.
Cure Perform a vertical alignment procedure. refer to chapter 6.6, Adjustments.

Repair and Service
7 Symptom: Hard disk doesn’t work
Symptom Hard disk doesn’t work
The end of the boot message looks as follows:
Wait until disk HD0 is ready

1 (Can not select [11])
** Error, Drive C: not ready
mon>
The cursor at the keypad is blinking; the red CPU LED lights up
Reason • Wrong SCSI address coding (only for new installed hard disk!).
• Bad contacts of cable connector.
• Possibly missing power supply for hard disk
• defective hard disk.
Cure • Type "dos" on monitor level (Drystar_C:\mon <enter>; Mon>DOS

<enter>) to be able to execute dos commands on monitor level. The
command "dir" should in any case give you the contents of the hard
disk if the connection can be achieved.
Type "he" to get more information on the "mondos" tool. Type "quit" to
leave the mondos level.
• If command "dir" doesn`t work check cable connection to the hard disk
and power supply.
• Replace hard disk or CPU if necessary
7.1 Software Installation / Configuration from Scratch
In case of troubles during installation or repair, it is required in certain cases to reconfigure the
printer or to install the software from scratch.
Enclosed a brief instruction:
7.1.1 Software Installation from Scratch
Tools needed: Laptop; IMOS Drystar 3000; Device SW (e.g. rel 1.95)
Proceeding:
• Start IMOS Drystar 3000
• Make a backup
• Select INSTALL SW: Reinstall System (see HELP IMOS Drystar 3000 for more information)
• Insert the floppies as requested
• Make a restore of the TH data only
• Make a new configuration (see next topic)
7.1.2 Configuration from Scratch

Repair and Service
Tools needed: Laptop, IMOS Megacon; possibly IMOS DICOM and / or MPS
Proceeding:
• Deletet all .a00, .c00 and .u00 files on the C: and D: partition
• Start IMOS Megacon
• Select for input / output / network the required modules. Choose "force pin" at the
different inputs/outputs.
• Use IMOS DCM or MPS to configure other network connections if required.
• Either make a selective restore of the LCD and MNU .U00 parameters or make a new
customisation of the printer, if required.
8 Troubleshooting Ethernet failures

Symptom: No printing via Ethernet
Reason:
HARDWARE
• Cabling (Coax not RG-58; short circuit; not connected, not terminated by 50 Ohm
terminator)
• BER board defective
• MAU (see green LED = power. Off means BEN or MAU problem) defective
• Drop cable, internal Drystar 3000 Ethernet cable. defective
SOFTWARE
• Ethernet not configured
• Problem in ART table (mismatch of small/capital letters; typing error)
• mismatch of apip_dest_names.
• Not enough diskspace for the network user 4 (or 5 to 9) in the printer where you want to
print the image.
Tools for troubleshooting:

TROUBLESHOOTING HARDWARE
⇒ Make a reset of the printer. Start "rem" (logbook) on terminal level. Type "go" and have a
look to the first page of information. You should get something like:
TNX ethernet address 00-66-00-27-6f-00 (=BEN ethernet adddress)
TNX selftest MAC okay (=one function of BEN SONIC chip)
TNX selftest ENDEC okay (=encoder/decoder function of SONIC chip)
TNX selftest cable okay (=check of fuse and cable)
TROUBLESHOOTING SOFTWARE
• look to the whole customization list: type NVE at the AOS shell prompt. You have to get
ETHXXX21 driver at the end. Otherwise it seems that Ethernet is disabled.
• type "adv" to get the whole list of all Ethernet nodes in your network ("adv" means
"advertise").

Repair and Service
9 Bus error
• Start IMOS Drystar 3000. No connection will be established. Select "Terminal"
Possible message: "RC" or "mon"*
• Perform a reset on the VME CPU or type "res"
• Stop the system boot up before the application SW will be started: Press ENTER key as
soon as the "AOS started" message appears.
• Remove all VME interfaces except the CPU
• Perform a reset: Now the system should boot up without bus crash. If a bus crash occurs
now, remove the NIP and BER board, too.
• Insert one interface after another. Make a reset in between. Like that the faulty interface
can be detected.
*In case a bus crash register dump is displayed, the following list will help to troubleshoot:
By looking on the "fault address" you can verify in the listing below the "fault" address
Address - Range Device Address - Range Device

00000000 - 07FFFFFF Memory module F7FE8400 - F7FE87FF CPU board
10000000 - 17FFFFFF Memory module F7FE8800 - F7FE880F BER
17800000 - 17FFFFFF LUT NIP F7FE8880 - F7FE888F BER
D0000000 - D7FFFFFF NIP F7FE8900 - F7FE89FF CPU board
E0000000 - E00FFFFF VSI F7FE8A00 - F7FE8AFF BER
EA000000 - EA1FFFFF COS board F7FE8B00 - F7FE8B1F NIP
EA200000 - EB000000 AIC board F7FE8C00 - F7FE8EFF CPU board
EF004000 - EF004800 AIC board F7FE8F00 - F7 FE8F0F BER
F2000000 - F2FFFFFF BER board F7FE8F20 - F7FE8F2F BER
F7FD0000 - F7FDFFFF CPU board F7000000 - FFEFFFFF CPU board
F7FE8001 - F7FE82FF CPU baord
F7FE8300 - F7FE83FF BER
Remark: When an addressing failure occurs, this might have other causes than a
malfunctioning board on the corresponding address. E g. a - malfunctioning - board
that responds to an addressing cycle of another board.
9.1 Bus crash caused by COS board

COS boards < rev. E in a few rare circumstances (e.g. at very low temperature) can cause a
sporadic buscrash. The printer will automatically reset as long as the buscrash exists. A logfile
(IMOS Drystar 3000 → TOOLS → terminal; "log to file") will show
BUS ERROR at addr ea000000 (or from EA000000 to EA1FFFFF respectively).
It is recommended to install SW release 1.7 or higher in this case. Software rel. 1.7 contains a
software upgrade for the COS board. In case the problem is not solved with this measure,
replace the COS1 board to a board with rev. F or higher.


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Repair and Service

1 Troubleshooting: General ........................................................................... 2

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# Symptom Description Reason Refer to

2 An error message is displayed on the internal or Problem during printer 3

3 An error message as text is displayed on the Problem during printer 4

5 Image fault: Monitor at console and image Either problem of image 6

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2 Symptom: Printer does not start up properly

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3 Symptom: An error message is displayed on the internal or external display

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4 Symptom: An error message as text is displayed on the internal display

Symptom: Film runs askew through the decurl unit

- If one or more screws are missing:

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• insert a film in the film take over

• Close the film take-over unit.

• Lift the shaft slightly on the drive

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• Check the pressure on the film on

- In case of pressure differences:

Symptom: Film runs askew through the decurl unit

Cure: Correct positioning of the bearing block.

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• If this is not a permanent solution for the problem:

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5 Symptom: Drystar 3000 does not print. No error message is displayed.

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Network Protocol Drivers

For further information see section 8 „Troubleshooting Ethernet failures“

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6 Symptom: Image faults

The list of artifacts on the film is divided in following types of artifacts:

# Artifact Example Refer to

6.1 Contrast and density reproduction faults

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6.1.1 Dmin too high

Cure (1) Perform a film calibration. Refer to chapter 6.6

6.1.2 Dmax too high or too low

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Density measurement of Drystar films:

Reason • Film calibration not performed and/or

Cure (1) Perform a film calibration. Refer to chapter 6.6

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6.1.3 Density reproduction / Optimal perceivable not okay

Cure (1) Perform a film calibration. Refer to chapter 6.6

In case the customer complains about

This can be done by loading a

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Figure 5: ktbwd2n.tif test image

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6.1.4 Contouring visible; 'Landscaping'

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6.2 Line artifacts in transport direction

6.2.1 Dust stripes

This fault can best be observed in the flat3001.bla test image.

For cleaning instructions refer to section 6.2.1.1, page 21

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6.2.1.1 Check of Film for Dust Stripes and/or Scratches

Basic Rules for the TH Cleaning Procedure

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