Laser Problems Agfa Dlab

Problems with the Laser
and the Color Laser Recorder (FLR)
Revision Level: 02
LTN: 20030610101419
Date: 10.06.2003
Problems with the Laser and Laser Recorder (FLR) Rev. 02
REVISION LEVELS
Rev. Remarks Date Name

00 New document 27.08.02 Ogiermann
01 Document revised and updated: 03.03.03 Conrads
− Revised struc ture
− SW error me ssages (version 7.50U) updated and new structure
− PBL error “D ensitometer: less than 5 measuring values” added
− Image error “B lue shadows” removed
− Description o f error message “PR: laser power green / blue to
high / too low” revised
(LTN: 20030303102631; Author: C. Conrads)
− Description o f error message “PR: failure of the 24V AOM supply
(PO assembly)” updated
(from LTN: 20030107155326; Author: A. Franke)
− Description o f error message “PR: AOM characteristic curves not
loaded” updated
(LTN: 20020124145501; Author: A. Franke)
− Image error c aused by “Laser oscillation” added
(LTN: 20030128111311; Author: M. Vietz)
− Chapter “Req uired information exchange prior to replacement of
the laser or color laser recorder” added
(LTN: 20020916105921; Author: T. Weiss)
− Chapter “Rep lacement of the color laser recorder (FLR)” updated
− Chapter “Rep lacement of the laser” updated
− Chapter “Rep lacement / adjustment of the AOM” updated
− Chapter “Rep lacement / adjustment of the Mainboard” updated
(LTN: 20030116103623; Author: B. Weigelt)
02 Section 1.2.6 “Blurs, color seam” 10.06.03 Conrads
Text “... (only possible in vertical direction = fast-scan). ) ... ” corrected
into “... (only possible in horizontal direction = fast-scan) ...”
2 AGFA d-lab
Contents
1. Error Messages, Image Errors, and Error Analysis .................................................................................. 5

1.1. Software Error Messages (Version: 7.50U) .....................................................................................................5
1.1.1. Error listing for the subjects laser and laser recorder................................................................................................... 5
1.1.2. “PR: Laser power drift green / blue, working point is being set, please wait ...”......................................................... 8
1.1.3. “PR: Laser power green / blue too high / too low” ...................................................................................................... 8
1.1.4. PBL error “Densitometer: less than 5 measuring values”............................................................................................ 9
1.1.5. “PR: Failure of the 24V AOM supply (PO assembly)” ............................................................................................... 9
1.1.6. “PR: AOM characteristic curves not loaded” ............................................................................................................ 11
1.2. Image Faults / Artifacts ...................................................................................................................................13
1.2.1. colors blue / green are missing................................................................................................................................... 13
1.2.2. Lines crosswise to the transport direction.................................................................................................................. 13
1.2.3. Noise .......................................................................................................................................................................... 13
1.2.4. White short lines in transport direction...................................................................................................................... 13
1.2.5. White prints in combination with the message “Image allocation error”................................................................... 13
1.2.6. Blurs, color seam ....................................................................................................................................................... 14
1.2.7. Laser power fluctuations (“wood block effect”) ........................................................................................................ 14
1.2.8. VIPS board interference............................................................................................................................................. 14
1.3. Error Analysis ..................................................................................................................................................14
1.3.1. Determine the assembly which causes the problem: Scanner / VIPS / Printer .............................................. 14
1.3.2. Analyze X-print / gray print....................................................................................................................................... 15
1.3.2.1. Error group 1 ......................................................................................................................................................... 16
Error: Horizontal stripes, light or dark................................................................................................................................ 16
Error: Vertical stripes, one or more, light, may be colored, usually blurred....................................................................... 16
Error: Horizontal stripes, regular intervals ≤1.1 mm (d.lab.3) or ≤0.8 mm (d-lab.2), light, may be colored, sharp,
probably locally (Polygon banding)......................................................................................................................... 16
Error: Individual lines are printed displaced, irregular spacing, displacement up to 40 mm.............................................. 17
1.3.2.2. Error group 2 ......................................................................................................................................................... 17
Error: Streaks, light or dark, and streaks change direction (“Fabry-Perot effect”) ............................................................. 17
Error: Fine meandering structures, parallel in spaces of a few millimeters, probably with changes of direction,
not visible in every print (“worm effect”)................................................................................................................ 17
1.3.2.3. Error group 3 ......................................................................................................................................................... 17
Error: Fine horizontal stripes, colored, without visible structure (laser noise) ................................................................... 17
Error: Color separation green (magenta) is not printed or printed only faintly .................................................................. 18
1.3.2.4. Error group 4 ......................................................................................................................................................... 18
Error: Fine horizontal stripes, colored, without visible structure (laser noise) ................................................................... 18
1.3.2.5. Error group 5 ......................................................................................................................................................... 18
Error: Analog to error group 3, however for GREEN and BLUE ...................................................................................... 18
1.3.2.6. Error group 6 ......................................................................................................................................................... 18
Error: Vertical lines in the color separation show poor color coverage.............................................................................. 18
Error: Horizontal lines in the color separation show poor color coverage.......................................................................... 18
1.3.2.7. Error group 7 ......................................................................................................................................................... 18
Error: Vertical lines show roughness/serrated edges (jitter) ............................................................................................... 18
Error: Vertical lines with ghost image, strong blurs or color seams ................................................................................... 19
1.3.2.8. Error group 8 ......................................................................................................................................................... 19
Error: Vertical line does not correspond to the nominal size.............................................................................................. 19
Error: Horizontal line does not correspond to the nominal size.......................................................................................... 19
2. Required Information Exchange Prior to the Replacement of the Laser or Color Laser Recorder ...... 19
3. Replacement of the Color Laser Recorder (FLR) .................................................................................... 20
3.1. Preparation .......................................................................................................................................................20
3.2. Color Laser Recorder, Dismounting ..............................................................................................................21
AGFA d-lab 3
3.3. Color Laser Recorder, Mounting ................................................................................................................... 22

3.4. Starting Operation........................................................................................................................................... 23
3.5. Calibrating the New Color Laser Recorder .................................................................................................. 33
4. Replacement of the Laser........................................................................................................................... 36
4.1. Introduction...................................................................................................................................................... 36
4.2. Design of the Adjustment Position ................................................................................................................. 37
4.3. Replacing the Laser ......................................................................................................................................... 38
4.4. Adjustment of the Fiber Coupling.................................................................................................................. 40
4.5. Error Case 1 ..................................................................................................................................................... 44
4.6. Error Case 2 ..................................................................................................................................................... 45
5. AOM Replacement / Adjustment ............................................................................................................... 46
5.1. Replacement of the AOM Drivers .................................................................................................................. 47
5.2. Adjusting the Offset and Gain ........................................................................................................................ 48
5.3. Loading the Default LUT ................................................................................................................................ 51
5.4. Determining the Specific LUTs....................................................................................................................... 52
5.5. Error in the Adjustment.................................................................................................................................. 53
5.6. Fastening the AOM Driver ............................................................................................................................. 54
5.7. MBL / PBL Calibration................................................................................................................................... 54
6. Replace / Adjust the Mainboard ................................................................................................................ 55
6.1. Saving Setup Values (if still possible)............................................................................................................. 56
6.2. Replacing the Printer Mainboard .................................................................................................................. 57
6.3. Transmit Software and Setup Values to the Printer Mainboard ................................................................ 58
6.4. Tests: ................................................................................................................................................................. 62
4 AGFA d-lab
1. Error Messages, Image Errors, and Error Analysis

The following listing of symptoms, causes and solutions summarizes the present level of information
(01/2003) about problems with the laser and laser recorder (= optical module).
The procedures mentioned in the chapter Error Analysis should allow a more accurate determination of the
causes for problems in the field.
1.1. Software Error Messages (Version: 7.50U)
1.1.1. Error listing for the subjects laser and laser recorder
Column 1 (A, B, C) shows the weighting of the problem

Column 2 shows the error code displayed in the menu Info
Column 3 shows the cause
Column 4 shows the solution
ERROR CODE ERROR MESSAGE (CAUSE) CORRECTIVE ACTIONS
A LA_AOMA001 no AOM LUT's loaded determine AOM-LUT's
C LA_AOMC002 internal error while determining AOM LUT's
C LA_AOMC003 AOM mirrors in wrong position set mirrors to correct position
C LA_AOMC004 AOM mirrors in wrong position set mirrors to correct position
C LA_AOMC005 laser power for AOM-LUT measurement cannot be set check mirror position and gas laser
A LA0000A004
A LA0000A005
A LA0000A015
A LA0000A016
A LA0000A017
A LA0000A018
A LA0000A019
A LA0000A020
A LA0000A021
A LA0000A022
A LA0000A023
A LA0000A024
A LA0000A027 power ratio GN/BL too high check gas laser
A LA0000A029 laser power GN/BL too low check gas laser and fiber coupling
A LA0000A030 PR: no ignition of gas laser check gas laser: key switch, connectors, main switch
A LA0000A031 PR: no ignition of gas laser check gas laser and its power supply
A LA0000A034 PR: working point of gas laser cannot be set check gas laser and its power supply
A LA0000A035 PR: no laser light GN/BL detected check shutter of gas laser, check fiber coupling
A LA0000A036 PR: laser light of gas laser is saturated check power monitor PCB
B LA0000B004 PR: power drift of laser light GN, working point is being set wait: working point is being set
AGFA d-lab 5
B LA0000B005 PR: power drift of laser light BL, working point is being set wait: working point is being set
B LA0000B028 PR: ignition procedure of gas laser, please wait ignition procedure of gas laser, please wait
B LA0000B033 PR: ignition procedure of gas laser, please wait ignition procedure of gas laser, please wait
C LA0000C009
C LA0000C010 PR: laser power RD cannot be set nominal power is higher than possible, check nominal power
C LA0000C011 PR: laser power GN cannot be set nominal power is higher than possible, check nominal power
C LA0000C012 PR: laser power BL cannot be set nominal power is higher than possible, check nominal power
C LA0000C013 PR: communication error check connectors and cables

wrong module-ID (PE), check firmware in print engine,
C LA0000C014
reinitialize the Printer (STOP)
PR: power ratio GN/BL too high - paper calibration problems
C LA0000C032
possible
C LA0000C037
C LA0000C038
C LA0000C039
C LAKOMPC001
C LAKOMPC002
A LAMO01A001 PR: no laser light RD detected check connectors, cables and power supply
A LAMO01A006 PR: working point of laser diode cannot be set check power regulator, cables, power supply and BOL-sensor
A LAMO01A010
A LAMO01A013 PR: laser power RD too low check power regulator, cables, power supply and BOL-sensor
A LAMO01A018 PR: laser power RD too high check power regulator, cables, power supply and BOL-sensor
A LAMO01A021 PR: laser power cannot be set use different (lower) power for RD
A LAMO01A024 PR: timeout power regulator RD
A LAMO01A027 PR: working point cannot be set
A LAMO01A030 PR: failure during initialization of laser diode check power regulator, cables, power supply and BOL-sensor
A LAMO01A033 PR: no laser light RD detected check power regulator, cables, power supply and BOL-sensor
A LAMO01A034 PR: monitor diode RD is saturated check power regulator, cables, power supply and BOL-sensor
A LAMO01A035 PR: power regulator RD defect check power regulator, cables, power supply and BOL-sensor
C LAMO01B016 PR: power loss of laser diode
C LAMO01C006 PR: laser power RD unstable
C LAMO01C016 PR: power loss of laser diode
A LAMO02A002 PR: no laser light GN detected check fiber alignment and shutter of gas laser
A LAMO02A007 PR: working point GN cannot be set check power stability GN and power regulator GN
A LAMO02A011
A LAMO02A014 PR: laser power GN too low check fiber alignment
A LAMO02A019 PR: laser power GN too high check power regulator, check power PCB
A LAMO02A022 PR: working point GN cannot be set use different (lower) power for GN
A LAMO02A025 PR: timeout power regulator GN
A LAMO02A028 PR: laser power GN cannot be set
6 AGFA d-lab
A LAMO02A031 PR: failure during initialization of laser GN check power regulator GN
A LAMO02A037 PR: no laser light GN detected check shutter of gas laser, check fiber coupling
A LAMO02A040 PR: monitor diode GN saturated check power regulator GN
A LAMO02A043 PR: power regulator GN defect check power regulator GN
C LAMO02B017 PR: power loss of laser GN
C LAMO02C007 PR: laser power GN unstable
C LAMO02C017 PR: power loss of laser GN

check power regulator BL, check shutter of gas laser, check
A LAMO03A003 PR: no laser light BL detected
fiber alignment
A LAMO03A008 PR: working point BL cannot be set check power regulator BL and power stability BL
A LAMO03A012
A LAMO03A015 PR: laser power BL too low check fiber alignment
A LAMO03A020 PR: laser power BL too high check power regulator BL, check power PCB
A LAMO03A023 PR: working point BL cannot be set use different (lower) power for BL
A LAMO03A026 PR: timeout power regulator BL
A LAMO03A029 PR: laser power GN cannot be set
A LAMO03A032 PR: failure during initialization of laser BL check power regulator BL and power stability BL
check shutter of gas laser, check fiber coupling, check power
A LAMO03A038 PR: no laser light BL detected
regulator BL
A LAMO03A041 PR: monitor diode BL saturated check power regulator BL and power PCB
A LAMO03A044 PR: power regulator BL defect check power regulator
C LAMO03B018 PR: loss of laser power BL
C LAMO03C008 PR: laser power BL unstable
C LAMO03C018 PR: loss of laser power BL
A LAPOLYA001 PR: polygon is not running at nominal speed check polygon/polygon driver
AGFA d-lab 7
1.1.2. “PR: Laser power drift green / blue, working point is being set, please wait ...”
Five possible causes for this problem:

1. The fiber coupling may be loose (adjustment error, measures: fiber adjustment and correct fastening).
2. The fiber coupling may be poorly adjusted (adjustment error, measures: fiber adjustment and correct
fastening).
3. High frequency interference may falsify the measuring signal of the monitor diodes (hardware problem,
can be checked with the script HF_test_AOM_monitordiodes.txt, measures: replacement of the color
laser recorder).
4. The fiber optic cable may be sensitive to movements (hardware problem, can be checked with the script
check_fiber.txt, measures: replacement of the color laser recorder).
5. The measuring system "Monitor diode" may be faulty (check cable + plug, check the LFB distributor
including plug + cable, measures: replacement of individual components).
1.1.3. “PR: Laser power green / blue too high / too low”
A) Recommended procedure for error message “PR: Laser power green / blue too high”:
1. Check the Power Monitor board (are all voltages present?)

2. Check the setup values of the monitor diode gain (see below)
B) Recommended procedure for error message “PR: Laser power green / blue too low”:
1. Check the Power Monitor board (are all voltages present?)

2. Check the shutter at the gas laser (open? – Attention: Do not remove the fiber!)
3. Check the fiber adjustment
4. Check the cables at the LFB distributor for conductivity / short circuit
5. Check the setup values of the monitor diode gain (see below)
Adjusting the setup values for the monitor diode gain:

As a solution in the field we recommend to call up the script path:
Script Files/ Scripts for Service/Printer/Laser/“monitordiode_gain_setup.txt"
and to change the values for “monitor diode gain (green / blue)”. Values in a range from 0 to 1350 can be
entered. The script automatically offers an increase of 400 for both colors. If the difference to the maximum
value is less than 400, the value 1350 will be offered.
The following applies to the two cases “Laser power green / blue too high or too low”:
• Laser power green / blue too high – decrease the value by e.g. 400 (range 0 - 1350)
• Laser power green / blue too low – increase the value by e.g. 400 (range 0 - 1350)
Note: Due to a program bug the message “Laser power ... too low” may be displayed although the
power is actually too high. Then the procedure under B) will help. This program bug existed up to
and including Software Version 7.50P.
Important: After the setup values for the monitor diodes were changed the paper calibration process must be
carried out again right from the beginning! I.e. PBL with laser point on MBL paper. Then an MBL
on this paper. And afterwards calibrate all the other papers with laser point!
8 AGFA d-lab
1.1.4. PBL error “Densitometer: less than 5 measuring values”
In case of blooming on the image level caused by too much laser intensity in combination with high-speed
papers, the PBL error message: “Densitometer: less than 5 measuring values” will be displayed. The laser
power can be reduced by increasing the amplification values of the monitor diodes (green / blue).
We recommend the following procedure:
1. Check the amplification values in the database (close to saturation at 4095?)

2. Increase the setup values of the monitor diode gain (se below; accept the given values)
3. Restart the d-lab with “ON”
4. Print a PBL with laser point for all papers
Adjusting the setup values for the monitor diode gain:

Enter the script path Script Files/ Scripts for Service/Printer/Laser/“monitordiode_gain_setup.txt"
and change the values for “monitor diode gain (green / blue)”. Values in a range from 0 to 1350 can be
entered. The script automatically offers an increase of 400 for both colors. If the difference to the maximum
value is less than 400, the value 1350 will be offered.
Important: After the setup values for the monitor diodes were changed the paper calibration process must
be carried out again right from the beginning! I.e. PBL with laser point on MBL paper. Then an
MBL on this paper. And afterwards calibrate all the other papers with laser point!
1.1.5. “PR: Failure of the 24V AOM supply (PO assembly)”
• The yellow and magenta colors are missing

completely in the prints, the prints are only cyan
both AOM drivers, green and blue, defective
• Mixed colors are reproduced wrongly:
Red is not red but yellow

Blue is not blue but cyan
AOM driver Green defective
Red is not red but magenta

Green is not green but cyan
AOM driver Blue defective
• The test print of X-print.txt See:

does not show the pixel line for G and/or B, ServiceGUI/Scripts for Service/Testprints
• the color bars G and/or B are white.
• The black bars have a color cast.
• The colors magenta and/or yellow only appear This is an indication for an upcoming total
in the beginning (a few mm) of the two color failure of the drivers.
bars G and/or B. The rest of the color bar is (Failure within 1-2 days)
white. The rest of the color bar is white.
AGFA d-lab 9
All 6 colors and black are present. The green light fails to reach the paper The blue light fails to reach the paper
print has a completely green color cast. print has a completely blue color cast.
OK Not OK Not OK
The laser light ‚R‘ ‚G‘ ‚B‘ is The laser light ‚G‘ is missing The laser light ‚B‘ is missing
reproduced in the respective there is no exposure everything there is no exposure
complementary color cyan, is white everything is white
magenta, yellow.
‚Black‘ is black. ‚Black‘ is dark green. ‚Black‘ is dark blue.
The mixed color of ‚G+B‘ is red. The mixed color of ‚G+B‘ is yellow The mixed color of ‚G+B‘ is
The mixed color of ‚R+B‘ is green. since only blue light reaches the magenta since only green light
The mixed color of ‚R+G‘ is blue. paper. reaches the paper.
The mixed color of ‚R+B‘ is green. The mixed color of ‚R+B‘ is cyan
The mixed color of ‚R+G‘ is cyan since only red light reaches the
since only red light reaches the paper.
paper. The mixed color of ‚R+G‘ is blue.
For information about the subject “AOM replacement / adjustment” refer to page 46ff.
10 AGFA d-lab
1.1.6. “PR: AOM characteristic curves not loaded”
Error AOM LUT’s are only checked during

AOM characteristic curves not Printer initialization.
loaded
Cause Once a LUT (linear, default, or specific)

• There is no LUT on the Printer Mainboard, has been loaded this message can no
(neither linear, nor default, nor specific LUTs). longer appear.
There is no possibility to delete a LUT
• There is no LUT at all loaded! once it exists.
This should only happen on a brand-new PCB The only alternative is:
on which no SETUP values have been loaded. The Printer Mainboard is defective or the
script routine is interrupted during
loading/creating of the AOM LUT’s.
Analysis
• The contents of the LUT can be checked with
the script
read_AOM_LUT.txt
under: scripts for service\printer\laser
scripts_printer\Laser\aom and laser diodes
AGFA d-lab 11
LUT value pairs

Typical example for a default/specific LUT:
Print: diode-LUT Print: AOM-LUT green: Print: AOM-LUT blue: The pairs of values always
Print: 0 0 Print: 0 0
red: Print: 2114 57 Print: 2114 72
start with 0 0.
Print: 4228 488 Print: 4228 502 Linearly increasing value
Print: 0 0 Print: 6342 1238 Print: 6342 1244 pairs are a sign that only a
Print: 8456 2318 Print: 8456 2248 linear LUT is loaded,
Print: 2114 3370
Print: 10570 3693 Print: 10570 3539
Print: 4228 6860
Print: 12684 5376 Print: 12684 5106 e.g. 2100 2100
Print: 6342 9815 4000 4000
Print: 14798 7309 Print: 14798 6924
Print: 8456 12416
Print: 16912 9499 Print: 16912 8948 6000 6000
Print: 10570 14791
Print: 19026 11907 Print: 19026 11160 8000 8000
Print: 12684 17041
Print: 21140 14497 Print: 21140 13541
Print: 14798 19182
Print: 23254 17242 Print: 23254 16102
Print: 16912 21266
Print: 25368 20132 Print: 25368 18794
Print: 19026 23336
Print: 27482 23102 Print: 27482 21580
Print: 21140 25365
Print: 29596 26173 Print: 29596 24463
Print: 23254 27364
Print: 31710 29268 Print: 31710 27418
Print: 25368 29350
Print: 33825 32530 Print: 33825 30514
Print: 27482 31300
Print: 35939 35645 Print: 35939 33505
Print: 29596 33257
Print: 38053 38708 Print: 38053 36471
Print: 31710 35208
Print: 40167 41692 Print: 40167 39379
Print: 33825 37200
Print: 42281 44600 Print: 42281 42238
Print: 35939 39136
Print: 44395 47352 Print: 44395 45013
Print: 38053 41072
Print: 46509 49985 Print: 46509 47741
Print: 40167 43001
Print: 48623 52493 Print: 48623 50361
Print: 42281 44916
Print: 50737 54839 Print: 50737 52850
Print: 44395 46817
Print: 52851 57016 Print: 52851 55184
Print: 46509 48732
Print: 54965 59000 Print: 54965 57341
Print: 48623 50633
Print: 57079 60733 Print: 57079 59290
Print: 50737 52526
Print: 59193 62239 Print: 59193 61073
Print: 52851 54399
Print: 61307 63545 Print: 61307 62759
Print: 54965 56285
Print: 63421 64634 Print: 63421 64243
Print: 57079 58165
Print: 65535 65535 Print
Print: 59193 60051
Print: 61307 61882
Print: 63421 63705
Print: 65535 65535
LUT curve diagram

Typical example for a default/specific LUT:
R
RED: steep increase in the beginning and
then the curve remains on the high B
level G
Green / blue: S-shaped curve
Remedy
• The Printer Mainboard has been replaced ...
SETUP values must still be loaded/ checked:
Execute printer_setup_write.txt
(before that download the XILINKS and Printer
main program)
• In case of an error the default and specific LUT
must be loaded/created.
See description: Replacement of the AOM
drivers
• If the Printer Mainboard fails to save the LUT
(error still occurs), it must be replaced.
12 AGFA d-lab
1.2. Image Faults / Artifacts
This chapter only provides a rough overview of image faults.

In the following chapter Error analysis an exact determination of the image faults and their causes can be
made.
1.2.1. Colors blue / green are missing

Visible when “X-print” in the directory “scripts for service/ testprints” is printed
Also see error message “PR: Failure of 24V AOM supply (PO assembly)” page 9.
Cause: AOM driver, Video cable coming from the Printer Motherboard, or Printer Motherboard.
Check by interchanging the blue and green signal cables at the AOMs; if this has an effect on the missing
color, the defective part is behind the Motherboard.
If there are no changes the Printer Motherboard may be defective.
If an adjustment of the AOM is not possible, the “default characteristic curve” must always be loaded as a
provisional solution. This should provide for an acceptable production.
1.2.2. Lines crosswise to the transport direction

The effect of thin gray lines of increased density in laser writing direction and in regular spaces across the
entire print is called banding.
This may be caused by:
1. Print engine – caused by transport delays (gearbox, gear motor, belt units).
2. Polygon in the Color Laser Recorder – the cause may be rotation problems or a damaged polygon.
Line spaces are different for the 8“ and 12“ machines.
1.2.3. Noise
Noise is indicated by short, bight or dark areas within the pixel lines in fast-scan direction (horizontal) in
uneven intervals.
Noise is only caused by the Argon laser, i.e. it only occurs in the print areas with yellow and magenta
color portions!
(Verification possibility: printing of a color scale e.g.: script “regout_nbild.txt”).
1.2.4. White short lines in transport direction

May be caused by paper scrap, dust particles, or paper dust in the exposure gap.
In this case cleaning of the belt units and the paper transport section in front of it will solve the problem.
In certain cases the belt units must be replaced (by experience it is mainly the upper belt unit of the PE
that is affected).
1.2.5. White prints in combination with the message “Image allocation error”
This may be caused by the BOL sensor.
Procedure: Start an exposure with the script “regout_nbild.txt” in the directory “scripts for service/
testprints”. In the displayed window select script “Mode 4”.
In case of an error the graduated color bar (cyan, magenta, yellow, gray) has a stripy appearance instead
of a homogenous color change.
AGFA d-lab 13
1.2.6. Blurs, color seam

Blurs and color seams can be caused by poor pixel alignment.
This can be determined by printing an “x-print”. Readjust pixel shift (only possible in horizontal direction
= fast-scan).
If a deviation in horizontal direction (> 1 pixel) cannot be corrected, the laser recorder should only be
replaced after the customer complains!
1.2.7. Laser power fluctuations (“wood block effect”)

The internal oscillation of the gas laser (fluctuation of the laser power) results in stripes with changing
directions and spaces. Shape and color are similar to wood pattern.
This problem can easily be identified as the effect is not visible in the cyan color separation (red laser diode).
Procedure: Expose the test patterns x-print.txt and regout.txt. > pay special attention to the color bars.
Usually the oscillation of the green laser is quite distinctive and can easily be seen in the stripy structure of
the magenta color bar.
Remedy: Replace the gas laser.
If the effect also occurs in the cyan color, these effect is caused by electrical interference. In this case do not
replace the gas laser.
1.2.8. VIPS board interference

VIPS board interference may be determined by exposing prints in Register mode (without VIPS interference).
For this purpose use the script “regout_nbild.txt” in the directory “Scripts for Service / Testprints”.
1.3. Error Analysis

Below the description how to locate and solve problems which result in poor printing results.
1.3.1. Determine the assembly which causes the problem: Scanner / VIPS / Printer
The following procedure should first determine the component which causes the problem in the Printer
system. The prints must be analyzed.
The following prints are required:
• 1 negative print of film
• 1 file print of a digital data medium (file print)
• 1 x-print on large paper format (script “X_PRINT.TXT”)
• 1 graduated color print per register output (script “testprint_series.txt”, test print 7)
The scripts can be found in Service mode in the script directory “scripts for d-lab”.
Check on which prints the problem is visible.
The last line of the following table indicates which component may be faulty:
Problem present: X
Negative print X X X
File print X X
X-print X
Graduated color print X
Faulty component: Scanner VIPS board Printer
Scanner: See Repair Instructions Scanner Replacement of zoom / film drive components
VIPS board: See Repair Instructions PC Replacement of VIPS board / PC memory chips
Printer: See below for the description of further procedures.
14 AGFA d-lab
1.3.2. Analyze X-print / gray print

Analysis in which color channels the error occurs.
The following prints are required:
• 1 x-print on large paper format (script “x_print.txt”)
• 1 graduated color print per register output on large paper format (script “testprint_series.txt”, test print 7)
• 1 gray print per register output on large paper format (script “greyprint.txt”)
The exposure scripts can be found in the script directory “scripts for d-lab”.
AGFA d-lab 15
Problem present: X
Gray print X X X X X
Cyan wedge in X-print (red), #1 X X
Magenta wedge in X-print (green), #2 X X X
Yellow wedge in X-print (blue), #3 X X X
Pixel coverage field in X-print, #4 X X
Geometry field in X-print, #5 X X
Error group: 1 2 3 4 5 6 7 8 9
Column 9 and probably further columns are free for new combinations which we do not know yet. As soon as
they occur (or in case of deviations of the described ones) please send an error description and test print to
Gera.
1.3.2.1. Error group 1
Error: Horizontal stripes, light or dark

• Error location: Width from a few millimeters to some centimeters, recurring in fixed spaces (banding), the
interval is typically between 3 mm and 10 mm, banding is only a density effect and no color effect.
• Possible causes: Friction transmission of the PE defective: Free turning of the PE is impeded (paper
jammed, belt of the belt unit slipped off after paper jam).
• Troubleshooting: Replacement of the friction drive, if necessary remove the paper or reconnect the belt.
• Error location: Width from a few millimeters to some centimeters, single stripe in the print, effect visible in
different prints in different positions, some prints do not show this effect; the horizontal stripe is only a
density effect and no color effect.
• Possible causes: Friction transmission of the PE defective.
• Troubleshooting: Replace the friction drive.
• Error location: Single stripe, light, approx. 1 mm wide at the beginning or end of the sheet and at a
distance of approx. 2 cm to the respective sheet edge.
• Possible causes: Defective belt unit, adjustment out of tolerance.
• Troubleshooting: According to the error analysis of the gray print in the Headquarters!
Error: Vertical stripes, one or more, light, may be colored, usually blurred
• Possible causes: Dirty optical components of the laser recorder.
• Troubleshooting: Clean/replace the post-scan mirror, replace the laser recorder.
• Possible causes: Dirt in the exposure gap or close to the exposure gap (dust, hair, lit, cobweb, ...)
• Troubleshooting: Clean the exposure gap.
Error: Horizontal stripes, regular intervals ≤1.1 mm (d.lab.3) or ≤0.8 mm (d-lab.2), light, may be
colored, sharp, probably locally (Polygon banding)
• Error location: Width of the stripes is one line (magnifying glass), only in rare cases more than one line.
• Possible causes: Polygon defective
• Troubleshooting: Replace the laser recorder
16 AGFA d-lab
Error: Individual lines are printed displaced, irregular spacing, displacement up to 40 mm

• Error location: Happens more often in dry climate if there is no antistatic brush (which was introduced in
production in April 2002)
• Possible causes: Static discharges interfere with the BOL sensor.
• Troubleshooting: Retrofitting of the antistatic brush.
Attention: Error group 2 is quite rare, only occurs in older versions
Error: Streaks, light or dark, and streaks change direction (“Fabry-Perot effect”)
• Possible causes: Color laser recorder defective.
• Troubleshooting: Fix the laser diode heater of the laser recorder, replace the laser recorder.
Error: Fine meandering structures, parallel in spaces of a few millimeters, probably with changes of
direction, not visible in every print (“worm effect”).
• Troubleshooting: Replace the color laser recorder.
Error: Fine horizontal stripes, colored, without visible structure (laser noise)
• Error location: Production date laser recorder before Sept. 1, 2002 (insufficient criterion), 1.97 V ±0.05 V
are applied at INT_GREEN and 1.0 V ±0.2 V at COR_GREEN, fiber coupling adjusted.
• Troubleshooting: Replace the color laser recorder.
• Error location: 1.97 V ±0.05 V are applied at INT_GREEN and 1.0 V ±0.2 V at COR_GREEN.
• Possible causes: Faulty fiber coupling
• Troubleshooting: Check and adjust the fiber coupling.
• Error location: 1.97 V ±0.05 V are applied at INT_GREEN and 1.0 V ±0.2 V at COR_GREEN, the fiber
coupling is adjusted.
• Possible causes: Defective gas laser
• Troubleshooting: Replace the gas laser
• Error location: With the working point adjusted a signal of <0.5 V or >1.5 V is measured on test point
COR_GREEN and 1.97 V ±0.05 V are applied at INT_GREEN.
• Possible causes: Defective Mainboard
• Troubleshooting: Replace the Mainboard
• Error location: With the working point adjusted a signal of <1.90 V or >2.05 V is measured on test point
INT_GREEN.
• Possible causes: Defective cable
• Troubleshooting: Replace the cable
AGFA d-lab 17
Error: Color separation green (magenta) is not printed or printed only faintly
• Error location: Check the deflection mirror green on the laser recorder.
• Possible causes: The deflection mirror green on the laser recorder has moved in.
• Troubleshooting: Move out the deflection mirror green on the laser recorder.
• Error location: Interchange the video cable with the blue channel, interchange the AOM driver with the
blue channel, interchange the AOM cable with the blue channel.
• Possible causes: Mainboard defective, cable defective, AOM driver defective
• Troubleshooting: Replacement of the component
• Error location: Check the setup values for pixel shift or set on 00001111 in all color channels.
• Possible causes: Input of incorrect setup values.
• Troubleshooting: Correction of the setup values
Error: Fine horizontal stripes, colored, without visible structure (laser noise)
• Error location / remedy analog to error group 3, however here GREEN must be replaced by BLUE
Error: Analog to error group 3, however for GREEN and BLUE

• Error location / remedy analog to error group 3, however for GREEN and BLUE
Error: Vertical lines in the color separation show poor color coverage
• Possible causes: Setup values for pixel delay and pixel shift not adjusted precisely enough.
• Troubleshooting: Determine the setup values for pixel delay and pixel shift and enter them in the
EEPROM.
Error: Horizontal lines in the color separation show poor color coverage
• Error location: The line of the red color separation (cyan) is shifted with respect to the other two.
• Possible causes: Polarizing filter for red works in the wrong octant.
• Troubleshooting: Turn the red polarizing filter by 2000 steps in the direction _UP, then restart with “ON”,
afterwards print a PBL with laser point on all papers.
Error: Vertical lines show roughness/serrated edges (jitter)

• Error location: No lines in the gray print – in contrast to the Polygon banding.
• Possible causes: BOL sensor not correctly adjusted.
• Troubleshooting: Adjustment of the BOL sensor.
18 AGFA d-lab
Error: Vertical lines with ghost image, strong blurs or color seams
• Error location: This problem may occur with different intensities.
• Possible causes: Poor electrical connection
• Troubleshooting: Replacement of the video cable
Error: Vertical line does not correspond to the nominal size

• Possible causes: PE drive too slow, blocked by particles, defective electronics
• Troubleshooting: Remove particles, replace the PE Control board PE (PE_GS01), replace the PE
gearbox.
Error: Horizontal line does not correspond to the nominal size

• Error location:
• Possible causes: Defective Polygon drive, defective control.
• Troubleshooting: Replace the Polygon driver (behind PE_GS01), replace the PE Control board
(PE_GS01).
2. Required Information Exchange Prior to the Replacement of the

Laser or Color Laser Recorder
Prior to the replacement of the laser or the color laser recorder (FLR) the following original prints and
information must be sent to Munich for evaluation and determination of the cause:
• a negative print of film

• a file print of a digital data medium (file print)
• an X-print on large paper format (script “X_PRINT.TXT”)
• a print of the script “REGOUT_NBILD.TXT” in mode 4
• LOG files
• error description
• when and how often the laser / color laser recorder has been replaced before
Additionally required information in case of Laser problems:

• laser operating hours
• laser current (QUICK_CHECK_LASERMODULE.TXT)
And before that the scans of these images should be sent to GSOML Munich via e-mail.
At the same time the serial numbers (FN) of laser / color laser recorder and machine (Printer), plus
installation date and information about service activities on the machine are required. Furthermore, all return
shipments of lasers and color laser recorders should always include printed examples of the errors.
Important!
Only use the special packing boxes for the return shipment please, i.e. the box in which the spare part was
delivered. Make sure that the components are correctly packed (no bent fiber, etc.) and protected from
external influences (e.g. impact).
AGFA d-lab 19
3. Replacement of the Color Laser Recorder (FLR)

3.1. Preparation
Spare Part Number

• Color laser recorder d-lab.3 CM + 9.4150.1000.x
including fiber and AOM driver d-lab.2 CM + 9.4150.2000.x
without gas laser and laser power supply
• LTN “Replacing the laser and adjusting the fiber

coupling”
• LTN “Printer calibration with MBL and PBL”
• Repair instructions of the d-lab.2/3
Chapter\Printer\Setup, pixel alignment
• Service cables CM + 9.8060.9001.0
CM + 9.8060.9002.0
• Voltmeter
• Torch
• Wrist strap for working on PCBs
• Allan key size 5
• Wrench size 6
• Cable tie
• Serial number: Printer
• Serial number: FLR
Save the setup values

• Enter the ServiceGUI. The setup values should only be saved for
safety reasons.
• Scripts for Service\Setup\...
As an alternative the values can also be
or
scipts_d-lab\setup\... taken from the customer’s diskette and/or
the originally delivered diskette.
• Execute printer_setup_backup.txt In SW < 7.00R
Printer_setup_read.txt
and
execute pr_vers_setup.txt
Preparing the initialization of the new color laser recorder (FLR)

• Scripts for The script sets a flag on the Printer
Service\printer\laser\... Mainboard causing an extensive routine to
or be executed during the next initialization of
Scripts_printer\laser\polfilter the color laser recorder. (Takes a little
and monitordiodes longer, the correct edge of the polarizing
filter is tested)
• Execute The script automatically resets the flag to
Lasermodul_reset_initialisation the old flag status if the initialization was
_flag.txt. successful.
20 AGFA d-lab
3.2. Color Laser Recorder, Dismounting

• Shut down the d-lab or the printer alone.
• Pull out the TU
• Take out the sheet bridge, only in the d-lab.2.
• Remove the hood of the gas laser.
• Pull out the fiber from the gas laser.
− To do so, onl y loosen the small rear fastening
screw (1) slightly.
Gas laser
• Unthread the fiber from the cable harness
(umbilical cord) and place it on top of the color
laser recorder.
− Open the ind ividual links of the umbilical cord.
Fiber coupling shown with a 90° turn
• Disconnect the cables from the color laser

recorder:
− PE_GS01 (p rint engine) ST19

ST 7
ST 8
ST 9
ST21
− LA_GS01 (LF B Distributor)ST 6, KA 38 green
ST 7, KA 37 blue
ST 1, KA 73 +
grounding cable
− LA_GS05 (L/ D modulator) ST2, KA 63
ST1, KA 121 Here the cable must be disconnected from the color
laser recorder
BU1, KA32 red
− LA_BE04 (AO M amplifier, green)

KA 34AM IN green
KA 67
− LA_BE03 (AO M amplifier, blue)

KA 33 AM IN blue
KA 67
• Loosen the 3 fastening screws of the color laser Attention: There are plastic washers below the
recorder (Allan key size 5). screw heads – do not lose them!
• Lift out the color laser recorder.

− Use the pull-o ut handles in the cover.
Attention: Cables below the laser recorder!
AGFA d-lab 21
3.3. Color Laser Recorder, Mounting
Caution!
There are cables below the color laser recorder,
they must not be squeezed!
• Insert the new color laser recorder.

• Tighten again the 3 fastening screws (Allan key
size 5) of the color laser recorder.
− Put the plasti c washers back under the screw
heads.
− Torque 60 Nc m;
i.e. only hand-tight.
− As the screw s were secured with lacquer,
there are some remainders in the thread. This
resistance must be overcome.
At the open corner there may be a gap between the
• Between the color laser recorder and print color laser recorder and the print engine
engine a gap of approx. 1mm may exist at the
free corner.
See on the right.
• Plug in the cables see above.
• Fasten the fiber at the entrance to the umbilical Here you see 2 cable ties.
cord by means of cable ties and position the One is only for the fiber and the other one is
fiber inside the umbilical cord. only for the cables.
• Approx. 5 cm from the end of the umbilical cord Do not tighten too much – risk of damage!
there is an opening. At this opening the fiber
must exit and then it must be positioned in the
cable duct below.
• Put the end piece of the fiber back in the gas See:
laser. LTN “Replacing the laser and adjusting the
− Push it to sto p position (small cam). fiber coupling”
− Tighten the s mall rear fastening screw.

• Position the cover cap of the fiber end piece
under the last cable clamp,
(this serves also as strain relief).
Checking the mirror position
• There are two knobs on top of the color laser

recorder.
Turn both to the green or blue marking
respectively.
They must not be in the red position.
22 AGFA d-lab
3.4. Starting Operation
Enter the SETUP values
• Connect the service cables.

• Pull the door switches.
• For the setup values refer to the label on the
cover of the color laser recorder (FLR).
• Switch on the d-lab.

It might start with error messages.
• Go to SGUI
scripts for service\setup
or
scripts_dlab\Setup
• Execute Printer_setup_set.txt .
Now all the setup values of the Printer are offered

for modification.
But only a few values will be changed.
All the other values will not be changed,
i.e. they will be skipped with NO.
• pixel-delay (red/green/blue) At the beginning the default values for pixel

....=> change? delay and pixel shift are entered:
YES Pixel delay: red, green, and blue = 0
- Red 0 OK Pixel shift: 1 to 4 = 0
- Green 0 OK 5 to 8 = 1
- Blue 0 OK
•
• Pixel-shift (1-8) ... => change? •

YES
- Pixel-shift (1) 0 OK
•
AGFA d-lab 23
• • Monitor diodes gain •

(red/green/blue):
... => change?
YES
•
• • Monitordiode gain (red): ... •

(Machine offset RED)
- This value is fixed.
Always enter 654.
• • Monitordiode gain (green): ... In d-labs prior to production period

(Machine offset GREEN) January/2002 (SN 01.02 xxx xxxxx)
incorrect setup values may be entered.
enter the value of the label Therefore the correct value on the
label must be marked as “corrected”.
• Monitordiode gain (blue): ... If this is not the case, 583 must be
(Machine offset BLUE) added to the label value.
enter the value of the label Should the resulting value be >1350,
enter 1350 maximum.
Example 1:
Label value 900 corrected
Enter 900 in the script
Example 2:
Label value 484
Enter 1067 in the script
( 484 + 583 = 1067)
In d-labs as of production period

April/2002 (SN 04.02 xxx xxxxx) the
setup values are correct. The marking
“corrected” is no longer used.
• Nominal Voltage red ... => The label value must be entered
change? in [mV]
(Nominal voltage RED) Example:
Label 2.07 V
enter the value of the label Enter 2070 in the script
• Save setup values on EEPROM?

YES
• Exit the ServiceGUI. Starting again activates the new setup
values.
• Start the d-lab with ON.
24 AGFA d-lab
Check: Position of the red polarization filter
Older color laser recorders (FLR) have no window,

in this case skip this step.
• The color laser recorder has a round window on

top with approx. ∅ 2 cm.
• Below you see the polarizing filter for red.
(A gray metal disk in vertical position
approximately 1 cm in front of the window.)
Illuminate the area with a torch.
Look down at an angle from the scanner to color
1
laser recorder:
• The polarization filter has a white marking. If the position is not

This marking must be in 12 o’clock position. correct ...
±1.5 h • Enter the ServiceGUI.
• scripts for
service\printer\laser
or
Script_files\scipts_printer\Laser\polfilter and
Monitordiodes
• Execute turn polfilter.txt.
− choose mo de: 1
− enter color: R
− enter directio n DWN or _UP
− enter numbe r of steps: approx. 2000
− Click OK (rep eat).
Now the polarizing filter is turning.
Repeat the rotation until the marking
is on “12 o’clock”.
− Stop
− Terminate th e script with exit.
AGFA d-lab 25
Adjusting the BOL sensor
Only required for the d-lab.3!
• The red laser beam must hit the center of the

BOL sensor (1) (PE_GS02).
•
• Cover the sensor (2) (but not the small mirror)
with a piece of paper. Now a bright red beam is
visible in the exposure gap and the red LED on
the board lights up.
• This beam is reflected by the reflecting mirror
and should hit the BOL sensor.
• If this is not the case, move the complete PCB
The BOL sensor is located behind the cast wall
(1) (4 Allan screws).
• As soon as the beam hits the sensor the red
laser beam and the LED switch off.
TEST
1. After the initialization of the color laser recorder
has been completed the red laser beam is
blanked and the LED of the BOL sensor is off.
2. If the sensor is now covered with a piece of
paper, LED (2) is on and the red laser beam is
again visible in the exposure gap.
d-lab.3 BOL sensor
In the d-lab.2 the BOL Sensor Board is

located precisely in front of and between
the flaps of the exposure gap and it is
not necessary to adjust it.
• Afterwards restart the d-lab with ON.
26 AGFA d-lab
Adjustment: Fiber coupling
• For this adjustment refer to the description in the Scripts for Service\Printer\Laser
LTN: “Laser replacement and adjustment of the or
fiber coupling”.
Scripts_printer\laser\gas laser
Adjust_fiber.txt
Target: max. monitor voltage
• Check the fiber transmission.

• Go to ServiceGUI
• Script_file\scripts_printer\Laser\gas laser\
• Execute check_fiber.txt. Tap the fiber with your fingers, just like
playing piano.
− The transmis sion is measured automatically Do not bend the fiber!
for approx. 30 sec. During this time you can (This test should simulate the
slightly move the fiber in the radius of the cable movements or vibrations which occur
harness (umbilical cord). during the replacement of paper
magazines or when the print engine is
− The resulting transmission changes are pulled out and pushed in.)
recorded automatically and evaluated at the Compare the monitor voltage before
end of the script. and during the fiber movement.
A variation of 4% is thereby
− The result sh ould be < 4%. permissible. (No comparison of input -
output)
AOM driver: Loading the default LUT
• Enter the ServiceGUI. This script loads the default AOM-LUT

for red, green, and blue.
• Scripts for Service\Printer\Laser
or This ensures that the following settings
have a defined initial status.
Script_files\scipts_printer\Laser\
aom and laserdiodes
• Start script
load AOM-LUT.txt
• At the prompt “Which LUT
(Linear = L, Default = D)”
answer with D.
•
• Wait for the script end: Script duration approx. 3 min.
answer: "AOM-LUT loaded"
AGFA d-lab 27
Adjusting the video voltage on the Printer Mainboard
• The printer must be running. This adjustment must be made

before the specific AOM-LUTs
• Go to ServiceGUI are determined.
• Scripts for service\Printer\Laser The video signal contains the image
or information which is sent to the FLR.
Script_file\scripts_printer\Laser\
register_mode
• Execute register_mode_on.txt.
− Switch OFF d ynamic noise reduction of laser?

YES
− insert re gister mode: 0 OK
− height re d : 0 OK
− height gr een: 0 OK
− height bl ue : 0 OK
− enter pos ition of first pixel:
100 OK
− enter pos ition of first pixel:  Depending on the Printer, d-lab.3 = 3494 or
3494 / 5000 OK d-lab.2 = 5000
• Terminate the script with Exit.
• Adjust video voltage RED

Connect a Voltmeter
GND plug housing for RED
Red measuring point BU1 red
• Adjust potentiometer R250 390 ±30 mV
• Adjust video voltage GREEN If those values are not reached

Connect a Voltmeter: (Printers up to production 2001), adjust at
GND plug housing for GREEN least a close value.
Red measuring point BU3 green The door switches must be pulled out for
measuring, otherwise the reading is 0 V.
• Adjust video voltage BLUE

Connect a Voltmeter:
GND plug housing for BLUE
Red measuring point BU2 blue
28 AGFA d-lab
• Scripts for service\Printer\Laser

or
register_mode
• Execute register_mode_off.txt.
− Switch ON dynamic noise
reduction of laser?
YES
AOM driver: Determine the specific LUTs
• Connect the service cables.

• Start script The script determines the specific AOM-
make aom-lut blue.txt LUT for blue and overwrites the default
values of the script “load AOM-LUT.txt”.
• At the prompt “Turn green/blue knob
on red position”
=> lift the respective knob on the cover of the Script duration approx. 5 min.
laser recorder by approx. 1 mm and turn it to the
red marking.
• At the end of the script turn the knob back to the The d-lab must only be restarted
with ON after all three specific
green position.
LUTs have been loaded.

make aom-lut green.txt LUT for green and overwrites the default
• At the prompt “Turn green/blue knob
on red position”
=> lift the respective knob on the cover of the
laser recorder by approx. 1 mm and turn it to the
red marking.
• At the end of the script turn the knob back to the
green position.
make diode lut red.txt LUT for red and overwrites the default
Even if one (or all 3) of the scripts for the specific

LUT is (are) not completed, i.e. stops with an error
message, the default LUT will be kept.
It is not necessary to load the default LUT again!
The Printer then works with the default values only.
(This does not have any visible negative effects on
the print results!)
• Restart the d-lab with ON.
AGFA d-lab 29
Test: FLR / color laser recorder

• Service cables no longer connected.
• Side door open, (door switch pulled out).
• Housing of the gas laser removed.
• Printer ready for printing.
• Note serial number of Printer and laser recorder.
• Go to ServiceGUI
• Scripts for service\Printer\Laser
or
polfilter and monitordiodes
• Execute This script checks the complete color laser
check_polfilter_monitordiodes_ recorder for correct functions.
laserdiodes.txt. Thereby the Printer and Processor are first
− enter SN printer: shut down and then started again step by
step.
− enter SN laser module:
− nominal v oltage red: update Script duration approx. 18 min.
EEPROM after measurement? YES
− Prosser c onnected? YES
− Scanner c onnected? YES Thereby the light source for the gas laser is
− Close shu tter of gas laser for closed for offset measuring, and then it is
offset-measurement. opened again.
Slide on gas laser up OK
− Disconnec t ST15 at printer Thereby the power supply for the red laser diode
power supply for offset- is interrupted for offset measuring, and then it
measurement (power supply of is connected again.
laser diode)!
Disconnect ST15 on Printer power supply. OK
− Connect S T15 at printer power
supply (power supply of laser
diode)!
Reconnect ST15 on Printer power supply. OK
• Open shutter of gas laser!
Slide on gas laser down OK
• Within the next 18 min the color laser recorder is Test results:
tested. During this time Printer, Paper Processor See information window,
and scanner are shut down and started again. or
(2x) C:\dlab\dlab‘version‘\logfiles\
check_polfilter_monitordiodes_
laserdiodes.txt (Example see next page)
− Polfilter, monitor diodes and The result must be OK.
laser diodes are OK. Otherwise repeat this test.
OK
− nominal v oltage red: update The measurement may result in a slightly
EEPROM after measurements? different value than noted on the label of the
YES color laser recorder (FLR).
Permissible tolerance 70% ...130%
Save the measured value with YES.
30 AGFA d-lab
Example: check__polfilter_monitordiodes_laserdiode.txt
# logfiles\check__polfilter_monitordiodes_laserdiode.txt Monday,
February 18, 2002 10:12:05
Printer: FN 105 lasermodule: FN 123
power supply is switched off..
starting up d-lab...
printer succesfully started
Minimum amplifier values:

OK: Red: 0000
OK: Green: 0000
OK: Blue: 0925
Maximum values during initialisation:
OK: Red: 2060mV
OK: Green: 2500mV
OK: Blue: 1274mV
Offset of monitordiodes Green and Blue:
OK: Green: 21mV
OK: Blue: 0mV
wait for polfilter-check...
Setup-value Unominal red: 1714 mV
Measured value Unominal red: 1751 mV
Tolerances: 70% - 130%
OK: nominal voltage red is 102% of set-up-value.
Maximum red: 2061mV
Minimum red: 18mV
polfilter dynamic range red: 1:108
OK: polfilter dynamic range red.
Maximum green: 2500mV
Minimum green: 114mV
Offset green: 21mV
Monitordiode green saturated; Minimum: 93mV
OK: polfilter dynamic range green.
Maximum blue: 1299mV
Minimum blue: 0mV
Offset blue: 0mV
polfilter dynamic range blue: 1:1299
OK: polfilter dynamic range blue.
monitordiodes : 0 (pre series)
OK: power 2500 2500 2500 is set.
OK: power 4095 4095 4095 is set.
OK: power 3000 3000 3000 is set.
OK: power 4095 4095 4095 is set.
OK: power 0 0 925 is set.
power stability; limit is 1%:
OK: laser power red stable: 0,1%
OK: laser power green stable: 0,5%
OK: laser power blue stable: 0,5%
gas laser:
laser powermonitor: 121
power monitor ST09 pin OP: 01210mV
laser current: 05,5A
power monitor ST09 pin OC: 0550mV
power supply is switched off...
starting up d-lab...
printer succesfully restarted
polfilters, monitordiodes and laserdiode are OK.
AGFA d-lab 31
Test: position laser line
• Go to ServiceGUI (=> information window)

R= permanent red
• Scripts for service\Printer\Laser G= permanent green
or B= permanent blue
general
• Execute check_line_position.txt.
• Insert Mode
R OK The same applies to green and blue.
The red line must now be visible precisely in the
middle (of height and width) of the exposure
gap. (1 min)
Length approx. 20 cm
• Mount the cover of the gas laser again. Caution! Do not pull out the fiber!
32 AGFA d-lab
3.5. Calibrating the New Color Laser Recorder
Adjustment: pixel shift and pixel delay
• Restart the d-lab with “ON”. See:
• Insert the MBL reference paper. Repair Instructions d-lab.2/3

Printer chapter:
• Enter the ServiceGUI.
Adjusting the pixel alignment
• Scripts for Service\testprints
or
Script_files\scipts_dlab\testprints See:
LTN MBL and PBL
Note:
MBL and pixel alignment depend on each
other.
Without correct pixel alignment an MBL test
can be aborted since the change of bw/wb
areas is not sharp. (Densitometer measuring
error!)
Without a correct MBL the colors CMY and
RGB are not pure, the analysis of pixel
shift/delay is difficult.
TIP:
1. Adjust the pixel delay correctly.
2. Adjust the pixel shift with a precision of
approx. ½ pixel width.
3. Calibrate the MBL until it is OK.
4. Optimize the pixel shift.
• Execute X-print.txt. (Old term: testprint.txt)

• Analyze the position of the pixel lines CYAN-
− With respect to the default values
MAGENTA-YELLOW (next to the letters RGB)
pixels may only be shifted to the left.
by means of the X-print (Exposure Print) and
adjust if necessary. − Reference is the pixel located furthest
left.
− All other pixe ls should be moved
closer to this pixel, so that CMY are on
one line.
− Fine tuning is quite easy to make when
you observe the mixed colors red, green,
blue.
(Wide pixel lines = 4 pixels in a row.) A
possible pixel displacement of CMY shows
clearly on the color fringes.
• Scripts for service\printer\laser\...

or
Scripts-printer\Laser \Pixelshift and pixeldelay\...
AGFA d-lab 33
• Execute With this script pixel delay and pixel shift are
pixelshift_and_pixeldelay.txt. offered for changing, always one after other.
− Enter your es timated corrections for pixel shift Pixel delay = shift by full pixels
and/or pixel delay.
Example 1
− Answer the q uestion: save to EEPROM? pixeldelay red oo
with NO Shift by 2 pixels to the left
pixeldelay red o2
− Print another X-print and analyze the result.
− If the results are OK answer the question: Pixel shift = shift by 1/8 pixel width
save to EEPROM? with YES
Example 2
− Afterwards re start the d-lab with ON pixelshift blue 00001111
Shift by 1/8 pixel to the left
pixelshift blue 10000111
Example 3
Shift by 3/8 pixel to the left
pixelshift blue 11100001
Adjustment: Begin of paper and center of laser line
• Scripts for Service\Testprints\... − We recomme nd to use 4“ = 102 mm

or paper.
Scripts-printer\printer generell\...
− This script pr ints a white test print with
• Execute Adjust BOP and center of a gray field.
laserlien.txt.
− Target:
White border on top: 2 mm
White border right and left must be
equal.
− Measure the border on top, as well as
right and left, and enter these values.
− The script pri nts another test print.
− The procedu re is repeated until the
results are satisfying.
34 AGFA d-lab
Saving the setup values
• Afterwards save the new setup values on

floppy/Zip and HD.
− Enter the Ser viceGUI.
− Scripts fo r Service\Setup\...
or
scripts_d-lab\setup\...
• Execute printer_setup_backup.txt In SW < 7.00R

Printer_setup_read.txt
and
execute pr_vers_setup.txt
Calibrate MBL/PBL
• After replacement of the color laser recorder See

(FLR) all papers must be calibrated again. LTN Printer Calibration with MBL and PBL
• MBL reference paper:
PBL test with laser point Ensure to take the time now
to do the complete procedure!
• MBL reference paper: Cutting this procedure just
MBL test to save time will result in
problems later during the
• All other papers: production.
PBL test with laser point
•
• Now the procedure of the color laser recorder Only in exceptions it may happen that
replacement is completed. the replacement of the color laser
recorder (due to a different weight of the
new unit) results in a different positioning
between print engine and transport unit,
which in turn may result in problems with
the paper running askew.
Wait at least 24 hours before you adjust
the height from PE to TU - during this
time the rubber suspension of the PE
may move back to its old position.
See Repair: Transport unit
AGFA d-lab 35
4. Replacement of the Laser

4.1. Introduction
Warning!
Looking directly into lasers of class 3B is
dangerous and may always be harmful for your
eyes.
For disconnecting the fiber from the laser the laser
must be switched off as otherwise laser radiation
may escape.
The fiber must only be disconnected at the laser

head and not at the Color Laser Recorder.
Keyboard
Mouse
SGUI or Voltmeter
Hex key; size 2, 3, and 5
Phillips screwdriver
Purpose of the adjustment
By means of this adjustment the factory-set pre-

adjustment of the fiber connection is adjusted for
maximum light transmission. A poorly adjusted fiber
affects the print quality as well as the service life of
the laser.
36 AGFA d-lab
4.2. Design of the Adjustment Position
Design of the adjustment position S

5
1. The fiber (1) with its integrated coupling 2
lens is held in a metal sleeve with locking 3
pins (N) to prevent turning.
2. The coupling attachment which has a rigid
connection with the laser consists of a
9
cylinder (2) in which 4 adjusting screws 8 1
with lock nuts are inserted (3-6). N

The rear adjusting screws (5 + 6) must not
be touched in the field! 6
3. Within the cylinder (2) there is another 4
cylinder (7) which is pressed against the Y N
adjusting screws by means of the clamping
screw (8) (with spring-loaded tip). (Illustration turned by 90°)
4. The fiber end piece (1) is inserted in
cylinder (7).
5. Clamping screw (9) (with spring-loaded tip)
holds the fiber end piece in a defined
position.
In this coupling attachment the laser beam with its

diameter of approx. 800µm is projected on a fiber 3+5
cross-section of 3µm via the lens integrated in the
fiber sleeve. Therefore the adjustment must be 7 2
made with extreme care! 4+6
Any approximate modification may cause loss of
light and will require the replacement of the laser.
8+9
AGFA d-lab 37
4.3. Replacing the Laser
Switch off the d-lab:

• Enter the ServiceGUI
under
Scripts for service\Initialisation
• Execute the script: Shut_down_dlab.txt
• Click "ignore errors"
• Switch the d-lab main breaker off.

• Remove the optional side table (if present).
• Dismount the cover of the fiber exit.

• Dismount the laser cover:
− Undo the scr ew
− Pull out the T U
− Move the cov er slightly to the right, keeping it
parallel, tilt it left and pull it out on the left hand
side below the print engine.
• Push the PE back in

• Push the TU back in
Laser without cover
Disconnect the fiber from the laser:

S
• Close the shutter (S) on the laser head 5
(upwards) 2
• If present: 3
Remove the hex socket screws (Y) completely
• Clamping screw (8) which positions the internal
sleeve must not be loosened 9
8 1
• Undo the clamping screw (9) by approx. 2 turns N
• Pull the metal sleeve of the fiber (1) carefully out 6
• Close the fiber by means of the attached metal 4
cap (metal cap hanging on the fiber in the cable Y N

duct)
(Illustration turned by 90°)
38 AGFA d-lab
Dismount the laser

• Remove the big mounting bracket from the
printer frame
2 x hex head 3
• Dismount the laser from the mounting bracket
3 x hex head 5
• Disconnect the laser cable at the laser power
supply and carefully unthread it upwards.
• Then take the laser out.
Mount the laser The laser has a flexible connection with the
• Insert the new laser, for this purpose first thread housing via the aluminum bracket.
the cable through the hole in the bottom plate.
Carefully insert the lower part of the cable in the The laser fan must not touch the Printer
housing either.
upper, left hand cable guide.
• Mount the laser on the mounting bracket Otherwise the following error may occur under
certain circumstances: Drift in the laser
• Fasten the mounting bracket on the printer power GN/BL. The working point is
frame. adjusted again
• Connect the cable on the power supply, roll up

the remaining length and place it between laser
power supply and printer power supply.
• Cables must not touch any movable parts of the
switching gear or the transport unit!
• Remove the cap from the fiber S
5
• Push the metal sleeve of the fiber (1) to the stop 2
position in the adjusted cylinder (7).
(The cam (N) of the metal sleeve must engage 3
in the groove of the cylinder (7).)

• Tighten clamping screw (9) and then turn it back 9 1
by ¼ rotation. 8
N
• Open shutter (S) downwards
6
• If present:
4
Screw the Allan screw (Y) back in
Y N
(Illustration turned by 90°)
AGFA d-lab 39
4.4. Adjustment of the Fiber Coupling
Two alternatives
For the adjustment the maximum value of the

monitor voltage for green is used.
There are two equal alternatives for measuring the

maximum value:
a) with Voltmeter
b) with the script adjust_fiber.txt
1. The alternative with the Voltmeter:
• To measure the monitor voltage connect the

Voltmeter to the Printer Mainboard (measuring
range DC / V):
• GND at ST 10
(brass housing of green, very right hand side)
• RED on INT GREEN
or,
MP 13 (for the old Mainboard version)
• Switch the d-lab on (main breaker)
• After the initialization wait approximately 5 min • The intensity of the laser source
until the laser has reached its temperature. changes during the warm up time.
• Enter the Service GUI
scripts for service\printer\laser
• Start the script adjust_fiber.txt − Adjusting rou tines are now taking
place in the machine, and for a while
− Click "ignore errors" the voltage reading on the Voltmeter
keeps changing.
• As soon as the displayed voltage reading is not − The script ke eps changing the green
changing any more, the following message is polarizing filter until a monitor voltage
displayed: of 520 mV has been reached. This is
“start to adjust now” and the adjustment then an optimum range for the
can be made, adjustment.
procedure see below.
40 AGFA d-lab
2. The alternative with the script:
• Switch the d-lab on (main breaker)

• After the initialization wait approximately 5 min − The intensity of the laser source
until the laser has reached its temperature. changes during the warm up time.
• Enter the Service GUI
scripts for service\printer\laser
• Start the script adjust_fiber.txt − Adjusting rou tines are now taking
place in the machine, and for a while
− Click "ignore errors"
the voltage reading on the Voltmeter
• As soon as the displayed voltage reading is not keeps changing.
changing any more, the following message is
− The script ke eps changing the green
displayed:
polarizing filter until a monitor voltage
„start to adjust now“ and the adjustment
of 520 mV has been reached.
can be made
− The informat ion and message
window now shows the monitor
voltages.
Print: actual: xxx mV max: xxx

mV
AGFA d-lab 41
Adjustment
• Only the screws (3) and (4) are used for the
adjustment.
• The screws (5) and (6) must not be touched!
They are too critical extreme risk to lose the
light beam.
•
• Before starting the adjustment loosen the lock
nut (K).
Thereby hold the respective adjusting screw
(3)/(4) by means of a hex key (size 2), to
prevent it from changing.
• Press against the cylinder with your finger and

observe the measured value actual: xxx
mV..
Press the cylinder in all 4 directions.
Determine the direction in which the measured

value increases, in this direction the adjusting
screw must be turned.
• Now adjust one adjusting screw to obtain a 3+5

maximum reading for the measured value. 7 2
Turn the adjusting screws only with a hex
key. Otherwise there is a risk to lose the original 4+6
position.
During the adjustment make sure to check the

tension of the clamping screws (8+9)
repeatedly:
8+9
Tighten the screws and then turn back by ¼
rotation to keep the spring effect.
• Repeat the same procedure for the other

adjusting screw.
42 AGFA d-lab
• Then repeat the complete adjustment procedure − The adjusted measuring value is
to improve the result. always a relative value based on the
Start the script adjust_fiber.txt position of the polarizing filter.
•
Example:
1. Adjustment cycle:
Start the script: 520mV
adjusted maximum value: 600mV
2. Adjustment cycle:
Start the script: 520mV
adjusted maximum value: 540mV
Only a minor improvement can be reached
during the second cycle
(from 520 to 540).
• Tighten the lock nuts (K).
To do so, hold the adjusting screws with the hex

key and tighten the lock nut by hand. (Fine
screw thread; tighten only hand-tight.)
Observe the measuring values at the same time.

The adjusted voltage value should not change.
• Mount the laser cover again.
• End
• The fiber adjustment is now completed.
• Setup values of the printer have not been
changed and it is therefore not necessary to
store them again!
• Mount the laser cover again.
• Enter the ServiceGUI
and under
Scripts for service\printer \laser
•
• Execute the script: statistic_laser.txt Reset of the statistics values cannot be
reversed!!
− Note the valu es: Observe the question in the window!
number of ignition and burning time
If the values are accidentally reset for the old
laser, the Service Technician loses this
− Answer the fo llowing questions with YES to information.
set the values for the new gas laser on zero. Only the manufacturer will then be able to read
(reset and initiate) the information.
(Useful for the evaluation of laser current and
laser power)
Upon return of the old gas laser to AGFA these
values must be included.
(For complaint and repair purposes)
AGFA d-lab 43
4.5. Error Case 1
ERROR: kein Laserlicht grün/blau meßbar

(no laser light green/blue can be measured)
In this case the printer fails to start and remains in
the initialization phase.
Error cause
This error message appears:
• if the light was "lost", or
• if there is not enough light arriving in the color
laser recorder.
•
• During the printer initialization the incoming light − The script sto ps with an error
is measured. If there is not enough light, the message since at least 520 mV must
initialization cannot be terminated and the script be measured at the monitor diodes.
adjust_fiber.txt cannot be carried out
either.
Adjustment with Voltmeter only

• Connect the Voltmeter on the Mainboard,
measuring range DC / V
− In contrast to the script in this case
− GND at ST 1 0
lower values then 520 mV may be
(brass housing of green, very right hand side)
measured on the Mainboard:
− RED on INT GREEN
or, Approximately 30 ... 3000 mV
MP 13 (for the old Mainboard version)
• The adjustment is now carried out as described

under Adjustment of the fiber coupling.
− Target of adj ustment: maximum monitor
voltage
• Start the d-lab again and use the script to check

the adjustment.
End of error case 1
• If it was not possible to determine a voltage
value proceed according to error case 2.
44 AGFA d-lab
4.6. Error Case 2
ERROR: kein Laserlicht grün/blau meßbar

(no laser light green/blue can be measured)
In this case the printer fails to start and remains in
the initialization phase.
Error cause
This error message appears:
• the light is "lost";
there is no more light arriving in the color laser − Measuring va lues 1 ... 10 mV is a
recorder. noise signal
• In contrast to error case 1 the voltage cannot
even be measured with the meter.
Adjustment on all 4 adjusting screws

A condition for the following steps is that the • The adjusting screws (3) and (4) have
technician is familiar with the fiber adjustment. only a minor influence on the coupling
Otherwise the laser should be replaced. of the laser light.
The adjustment is principally carried out as However, they have a major influence
described under Adjustment of the fiber coupling. on the optimization of the transmitted
light.
• In this case the rear adjusting screws (5) + (6) − The adjusting screws (5) and (6)
may be used in addition. have a very strong effect on the light
coupling.
• Here the target is to obtain a voltage value after
all by shifting the fiber in parallel.
The actual light coupling is only within
• For this purpose change the horizontal adjusting a range of approx. ¼ rotation.
screws (4+6) until a voltage reading is obtained.
The problem is to find this narrow
• Change the vertical adjusting screws (3+5) until
range.
a voltage value is obtained.
• Once a voltage reading has been obtained,
proceed with the optimization of the fiber S
5
coupling as described above.
2
9 1
8
N
6
4
Y N
End of error case 2
AGFA d-lab 45
5. AOM Replacement / Adjustment

This description refers to the color laser recorder
(FLR)
− with modifica tion level ≥ 5

− as of IV/2002
d-lab.2 with number L4.4150.2000.2
modification level ≥ 1
− as of IV/2002
d-lab.3 with number L4.4150.1000.3
modification level ≥ 1
− and script
AOM_driver.txt as of revision 1.2
Color laser recorder with type label
and modification sign
For the adjustment:

The d-lab must start up without any errors.
(No errors with respect to laser or color laser
recorder.)
The adjustment of the AOM driver is independent

of:
• the monitor diode values and the setup values

monitor_diode_gain green
monitor_diode_gain blue
• the optimization of the fiber coupling
• The drivers for green and blue can be adjusted
in any order.
• The adjustment of the AOM drivers is
completely independent of each other.
• Service cables CM + 9.8060.9001.

• CM + 9.8060.9002.
• Small screwdriver for potentiometers

• Allen key, size 6 / 8, open end wrench
46 AGFA d-lab
5.1. Replacement of the AOM Drivers
• Switch off the d-lab, main breaker off

• Pull out the print engine
• Dismount the AOM driver LA_BE 03 blue
and/or
the AOM driver LA_BE 04 green.
− Caution: The drivers get very hot in operation!
− Mind the insu lation disks when unscrewing the
drivers. The disks serve as electric isolation
with respect to the color laser recorder.
• As the potentiometers are difficult to access for
the following adjustment, the new drivers should
not be screwed down yet.
• Connect the new drivers electrically and place
them on top of the color laser recorder. Use an
electrically insulation base. If this is not done, 2 LA-BE03 AOM driver BLUE
the measuring result will be falsified. 3 LA-BE04 AOM driver GREEN
4 Fastening screws
• Connect the print engine via the service cable.
• Pull the door switches.
• Start the d-lab. The d-lab must start up without Alternative in undefined Printer situations:
any errors.
(No errors with respect to laser or color laser • Enter the Service GUI, shut down the
recorder. Without correct initialization of the Printer and start it up again.
color laser recorder the driver adjustment cannot
− Scripts for Se rvice\Initialisation \
be made.) shut_down pr.txt
− Scripts for Se rvice \
Printer\Initialisation \ start_up
pr.txt
AGFA d-lab 47
5.2. Adjusting the Offset and Gain
• Enter the ServiceGUI.

• Scripts for Service\Printer\Laser
• Execute AOM_driver.txt
• If the message “load linear LUT and delete The drivers for green and blue can be adjusted in
actual LUT“ comes up, confirm it with NO. any order.
Note:
The adjustment of the AOM drivers Green and
Blue are completely independent of each other.
• At the prompt “Turn green/blue knob to

red position”
lift the respective knob on the cover of the

color laser recorder by approx. 1 mm and turn it
to the red marking.
The knob must engage again completely!
• The values for 0%, 3%,100% are • Examples

shown in turns in the information 0% 3% 100%
window: Print: actual (absolute) 20 40 2000
0% 3% 100%
Print: actual (absolute) 100 150 3500
TIP: Functional test

At the same time you can see a cyclic red,
cyan, and white laser beam in the exposure
gap (depending on the mirror in the beam,
white has a lower intensity than red or cyan).
This indicates that the script and the AOM‘s
work correctly.
48 AGFA d-lab
0 % balance (OFFSET)
• On the AOM driver

turn the potentiometer +24 V ccw
until the lowest value is found at 0%.
= Minimum
Once the potentiometer is in stop position, a

slight clicking noise can be heard.
Then turn clockwise until the value
increases by one digit.
The lowest value at 0% must be > zero. If the value = zero
(the script does not show negative values)

• Abort the adjustment with the
potentiometer +24 V and set the
potentiometer to the left hand stop
position.
• The potentiometer RF Level ADJ must
be adjusted for the value 100% as
described below.
• Afterwards the default AOM-LUT must
be loaded as described.
• The specific AOM-LUTs must not be
determined then!
AGFA d-lab 49
100 % balance for GREEN (GAIN)
• On the AOM driver GREEN

turn potentiometer RF Level ADJ cw until the
highest value is found at 100%.
= Maximum
Of the maximum value found for GREEN Example for GREEN:
adjust the so-called 50 % difference value
found minimum at 0% = 100
GREEN = Minimum+[(Maximum–Minimum) x 0.5] found maximum at 100% = 2000
difference = maximum – minimum
= 2000 – 100
= 1900
50% of the difference = 1900 x 0.5
= 950
GREEN = 100 + [(2000 – 100) x 50%]
= 100 + 1900 x 0.5
= 100 + 950
= 1050
Adjustment 100% value on the potentiometer

RF Level ADJ = 1050
100 % balance for BLUE (GAIN)
• On the AOM driver Blue

turn potentiometer RF Level ADJ cw until the
highest value is found at 100%.
= Maximum
Of the maximum found for blue Example for BLUE:
adjust the so-called 75% difference value.
found minimum at 0% = 200
BLUE = Minimum+[(Maximum–Minimum) x 0.75] found maximum at 100% = 01200
difference = maximum – minimum
•
= 1200 -200
= 1000
75 % of the difference = 1000 x 0.75
= 750
BLUE = 200 + [(1200 -200) x 75%]
= 200 +1000 x 0.75
= 200 + 750
= 950
Adjustment 100% value on the potentiometer

RF Level ADJ = 950
50 AGFA d-lab
• These adjustment routines (see ) will be Adjustment aim:

repeated again until no more improvement for • Minimum at 0% display
the 0% value and the 100% value can be
• Maximum at 100% display
obtained.
(the value to be adjusted results from the
above mentioned formula)
This means the minimum for the 0% value
and the maximum for the 100% value must be
• Difference (delta) between the 0% and
determined again.
100% value > 200.
Usually the values are improved thereby.
− (this refers to the actual 100% value of
the script and not to the adjusted %-
value)
− (sometimes d elta values of 500 to
4094 can be reached)
• Terminate the Script with STOP

• Reset the button to the green marking
• If both AOM drivers have been replaced, repeat

this adjustment for the second driver.
5.3. Loading the Default LUT

(Look Up Table AOM)
• Start script This script loads the default AOM-LUT for red,
load AOM-LUT.txt green, and blue.
• Confirm the message “Which LUT (Linear = L, This allows the d-lab to work in general, even
Default = D)“ with D. without specific AOM-LUTs.
•
• Wait for the script end: Script duration approx. 3 min.
answer: "AOM-LUT loaded"
AGFA d-lab 51
5.4. Determining the Specific LUTs

(Look Up Table AOM)
This point will only be adjusted if it was impossible to

do the 0% balance.
Otherwise this step will be skipped!
• Start script These three scripts determine the specific

make aom-lut blue.txt AOM-LUT for blue, green, or red, and
overwrite the default values of the script
• At the prompt “Turn green/blue knob to “load AOM-LUT.txt”.
red position”
lift the respective knob on the cover of the

color laser recorder by approx. 1 mm and turn it Script duration approx. 5 min.
to the red marking. After approx. 1 min measuring values will be
displayed in the information window.
green position. If not an error occurred.
• Restarting the d-lab with ON is only necessary

after all three specific LUTs have been loaded.
• Start script If one the these 3 scripts is not executed

make aom-lut green.txt correctly, it can be skipped. The Printer then
works with the default values. In case of an error
• At the prompt “Turn green/blue knob to the default LUT is kept.
red position”
(This means that a possible optimization was not
lift the respective knob by approx. 1 mm and made.)
turn it to the red marking.
green position.
• Restarting the d-lab with ON is only necessary
after all three specific LUTs have been loaded.
• Start script
make diode lut red.txt
• At the end the d-lab must be started again with

“ON“.
• Then save the new setup values on Zip or HD.
− Enter the Ser viceGUI.
− Scripts for Se rvice\Setup\...
or
scipts_d-lab\setup\...
− Execute the s cripts Printer_setup_backup.txt.
52 AGFA d-lab
5.5. Error in the Adjustment
• Start the script again if the measuring value is

4095.
(Measuring error)
• There is no error message if the power supply
of the AOM drivers is not connected.
In this case only the measuring noise is
displayed
(approx. 50 mV)
Only 24 V errors in the Printer power supply are
indicated by the GUI.
• If the value fails to change when you turn the
potentiometer the AOM driver is most likely
defective.
• If all 3 measuring values are on almost the

same values e.g. zero or 2250
or if they only change slightly or not at all:
the AOM driver may be defective

or
the mirror shaft may be out of adjustment.
•
− In the latter c ase the position of the respective
mirror can be changed.
− Start the scri pt AOM_driver.txt again.
− Slacken the f astening screw at the knurled
knob.
− Now carefully turn the slotted screw in the
middle of the knob.
By this you turn the mirror shaft
directly!
− While doing t his observe the measuring value
and set the 100% value on its maximum.
− All three valu es: 0%, 3%, and 100% are
measured in cycles and displayed.
− If you were a ble to increase the values The hinged mirror directs the green and/or
blue beam to a 4th monitor diode LA_GS08
terminate the script.
for measuring purposes.
− Tighten the fa stening screw again at the If the mirrors are out of adjustment the
knurled knob. beam is not correctly guided to the
− Start the d-la b with ON. measuring diode
the measurement will be faulty.
− Repeat the c omplete adjustment.
AGFA d-lab 53
5.6. Fastening the AOM Driver
• Mind the electric isolation when screwing (4) the

AOM drivers to the laser recorder.
4 Fastening screws
• Two plastic insulation disks are inserted on the

left and right side of the holding plate. The collar
must be in the hole in the plate.
2
3
4
1 Color laser recorder

2 Holding plate
3 Fastening screw
4 Isolation disks with collar
5.7. MBL / PBL Calibration
• Test the MBL on the MBL reference paper.

• If the result is in tolerance, the AOM driver
replacement is completed.
• If the MBL result cannot be brought in tolerance 1. On MBL reference paper PBL with
a new calibration of all papers is required. laser point
Calibrate the MBL reference paper with “PBL 2. On MBL reference paper MBL
with laser point“.
3. All other papers PBL with laser point.
• The replacement of the AOM drivers is thus
completed.
54 AGFA d-lab
6. Replace / Adjust the Mainboard

Allan key, size 3
Open-end wrench, size 6
The PCB PF_GS01 (1) is located behind the front

panel
dlab2135,
• Switch off the Printer

• To open the front door open first the upper door
of the print engine
• Press the button (see arrow), to open the front
panel
dlab2101
Replacement is required in the following cases:

• Communication problems with the Main
Computer (read out of hardware and software
versions is no longer possible).
• Communication problems with the Printer
assemblies (cables have been tested and were
OK).
The error symptoms could be similar to those
generated by other units.
A clear indication for problems on the Printer
Mainboard is simultaneous lighting of all segments
in the segment display (88).
In order to check this jumper J5 must be plugged in.
For the testing of the Mainboard there is a script
available:
scripts for service/initialisierung/
pr_board_selftest.txt
• There may be different versions of the Printer
Mainboard (GS01) in d-labs:
− L8.8060.2000 .X only for d-lab.3
(X stands for a letter, no LED display)
AGFA d-lab 55
− L8.8060.2000 .0 only for d-lab.3

− L8.8060.2340 .0/1 only for d-lab.2
• L8.8060.2340.2 for d-lab.2/3 and net-lab.12
How this depends on the software is described in
the section Software transmission.
6.1. Saving Setup Values (if still
possible)
Usually it will not be possible any more to read out

the setup values.
Setup values are stored in the following locations:
• In the folder C:\DLAB\D-lab Version\ Logfiles,
File: printer_setup_protokoll.txt
• Diskette enclosed with the shipment,
File: printer_setup_write.txt
Attention:
The original setup values have probably been
changed since production start at the
customers’. This was necessary if assemblies
were replaced or machine parameters were
optimized. If the data, changed meanwhile,
have not been saved the two files still contain
the original data, i.e. as they were at the time
of shipment.
If saving is still possible then:

• Change in the program to Service GUI
• Execute the script scripts for
service/setup/
printer_setup_backup.txt. The script
printer_setup_write.txt
is automatically created and saved in the same
script folder. The file contains all setup values of
the Printer and the AOM LUT.
This script is used to restore the setup values
after replacement of the GS01.
• Determine the operation times of the gas laser:
Execute the following script in the Service GUI :
Scripts for service\printer\laser\
statistic_laser.txt
Note values (number of ignition and
burning time)
• Document the reasons for the Printer Mainboard
replacement by print examples if necessary.
• Start the script Scripts for service/
initialisation/Shut_down_d-lab, to
switch off the power supply to the Mainboard.
If the execution of scripts is no longer possible
due to a defect, switch off the machine.
56 AGFA d-lab
6.2. Replacing the Printer Mainboard
• Wear the antistatic wrist strap and ground it to

protect the components.
• Push the Printer Mainboard with it holder to the
left, to do so loosen the Allan screws (1).
• Unplug the connections on the PCB:
For plug 10 a size 6 open-end wrench must be
used.
• Disengage the 6 lugs, replace the PF_GS01 and
engage the new PCB again in the 6 lugs.
• Plug the connections back in:
Do not turn plug 10 too far.
• Fasten the holder of the Mainboard by means of
four Allan screws.
Check the jumper setting:
J1 - not plugged in dlab2102

J2 - not plugged in
J3 - plugged in (J1...J3 exists only on Mainboard
8.8060.2000.X)
J4 - not plugged in (BOOT)
J5 - not plugged in
(LED_ON, segment display on)
J6 - plugged in (R_CAN)
AGFA d-lab 57
6.3. Transmit Software and Setup

Values to the Printer Mainboard
(in this sequence)
• Switch on voltages:
Switch on d-lab, or execute the script Script
for service/initialisation/
start_up_d-lab.txt
Check the software on the Printer Mainboard

The following software elements are stored on the
Printer Mainboard, and in case of PCB replacement
they must be updated:
• Firmware Printer Mainboard (prhp.hex)
• Firmware XILINXS (prxi.hex)
• SETUP parameters of the Printer assemblies
On spare PCBs from stock there is usually an
unknown firmware version.
The setup values do not correspond either to the
repaired machine. (Usually default values)
Therefore a software check for the new Printer

Mainboard must be made:
• Check via Service / Firmware Version.

• Compare the displayed result with the required
version of the software package present in the
machine:
The firmware belonging to a certain software
package can be determined subsequently.
− Activate the W indows Explorer (via Watchdog)
− Open the file label.txt. Path:
C:\SoftwareVersion/PR/Install/
PR_Vxxx-y/label.txt
Information from Label.txt:

Here HP stands for prhp.hex and XI for prxi.hex
58 AGFA d-lab
Download XILINKS (prxi)

(by experience rarely necessary, takes about 5 min)
• Service
− Firmware D ownload
− LASER PRIN TER*PR
− xilinx pix el pipeline
• Search file under
− C:\Dlab\Dl abxxxx\Pr\Install\
Pr_Vxxx-y (see Note below)
− prxi.hex
• Path and file name are displayed in the upper
window after clicking Open
• Select download
After a few seconds a window opens:
Downloading Printer
• After the download an automatic reset is
executed, the voltages remain on.
Note:
y stands for 6,7,Z.

The main software packages also include the
different software versions for the different types of
the Printer Mainboard in the folder
SystemversionXXXXX/pr/install.
Always change to the respective path:

• V xxxxxx-6
for d-lab.3 with Mainboard 8.8060.2000.X
(X = letter, PCB has no LED indication, only old
machines)
• V xxxxxx-7
for all other d-lab.3, (PCB has an LED
indication)
• V xxxxxx-Z
for all d-lab.2 and net-lab.12
AGFA d-lab 59
Download Firmware (prhp.hex)

(if necessary, takes about 40 min)
This applies to all downloads:
By all means do not interrupt the download
otherwise it cannot be repeated!
Important note:
With the introduction of the main software 7.50x the
firmware structure of the Mainboard changed as
well.
A wrong download would make the board useless in
one case.
And in another case if a further update is required a
download of firmware would no longer be possible.
Therefore consider the following information:
• If with Service\ Firmware Version a

firmware < 1.04.xx was determined on the
replaced Mainboard, load prhp_kombi.hex if
the main software for the machine operation
should be 7.50x and higher.
• If with Service\ Firmware Version a
firmware < 1.04.xx was determined on the
replaced Mainboard, load prhp.hex if the
main software for the machine operation should
be 7.00x.
• If the determined firmware on the replaced
Mainboard is 1.04 and higher load prhp.hex if
the main software is 7.50x and higher.
If the machine is to be operated with a main
software of 7.00x (because it is already
installed), then the firmware must not be
updated.
Important! In this case an installation of the
software 7.00x must not be made as the
automatic download process would make the
board useless.
• Service
− Firmware D ownload
− LASER PRIN TER*PR
− HP printer main software+++
• Search file under
− C:\Dlab\Dl abxxxx\Pr\Install\
Pr_Vxxx-y
− prhp.hex ( or prhp_kombi.hex)
• Path and file name are displayed in the upper
window after clicking Open
60 AGFA d-lab
• Select download
After a few seconds a window opens:
Downloading Printer
Once the window closes again the software
download was successful.
Loading setup values (with AOM LUT)

• If the data of the diskette enclosed in the
shipment are to be loaded, copy the file
printer_setup_write.txt first with the
Windows Explorer to the folder Scripts/Scripts
for Service.
• Change to Service-GUI/Scripts/
scripts for service/setup/
printer_setup_write.txt
• Start the script with Execute
• At the end of the script answer the prompt Save
with YES
Attention!
This script loads the AOM LUT determined with the
removed PCB. If the PCB replacement was
somehow connected with a trigger problem of the
red laser, and/or the AOM green and blue, the AOM
characteristic curves must be determined again.
If the setup values are no longer available they can
be ordered again through the service from the
manufacturer by specifying the machine number.
(usually the following file has been saved there:
printer_setup_write.txt)
• Adjustment of the video voltages:
• Adjustment of the video voltages must be made
prior to the determination of AOM characteristic
curves.
• Execute Scripts/scripts for service/
printer/laser/register_mode_on.txt
(Answer the prompt – Switch OFF dynamic Für Bildmaler: Bezeichnung „neues
noise reduction of laser? – with YES) Printerbord“ nicht übernehmen.
• Accept the suggested values (0,0,0,0,100,5000)
• Connect the Multimeter at the respective point
and the plug housing (GND) (Illustration
lower circles)
• Adjust the video voltages with the respective
controls (Illustration upper circles)
• Adjust the following values:
red 390mV +/- 30mV
green, blue 365mV +/- 30mV
• Execute the script Scripts/scripts for
AGFA d-lab 61
service/
printer/laser/register_mode_on.txt
(Answer the question – Switch ON dynamic
noise reduction of laser? – with YES)
•
• Checking the software versions:
• Check the firmware version in the Service GUI,
compare as explained in the procedure above.
•
• Check the setup values:
• Start the script Scripts/scripts for service/setup/
printer_setup_backup.txt.
• Print a test print.
To do so execute Scripts/Scripts for
service/
testprints/X-print.txt
Evaluate the parameter (BOL, pixel shift, center
of laser line...) and correct if necessary. (In case
of correction save the SETUP values again.)
• Verify that jumper J5 of the Printer Mainboard is
open (risk of light reflection).
6.4. Tests:
• For safety execute script scripts for

service/initialisierung/
pr_board_selftest.txt again.
• Run a communication test between the Printer
Mainboard and the VIPS Board by executing the
script:
Script Files/scripts_Printer/
printer_general/test lvds short.txt
Message at the end:
Test ready /0 Error(s), LVDS-Interface OK.
• After the end of this script the machine program
must be started again with the ON button.
• Statistics values laser:
After replacement of the Printer Mainboard the
runtime statistics of the laser must be started
again. To do so execute the script:
Scripts for service\printer\laser
statistic_laser.txt
Answer the questions with YES so the values for
the gas laser are reset to zero. Counting of the
number of ignitions and operating hours starts
again.
62 AGFA d-lab

Laser Problems Agfa Dlab

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Laser Problems Agfa Dlab

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Problems with the Laser

and the Color Laser Recorder (FLR)

Rev. Remarks Date Name

1. Error Messages, Image Errors, and Error Analysis .................................................................................. 5

3.3. Color Laser Recorder, Mounting ................................................................................................................... 22

1. Error Messages, Image Errors, and Error Analysis

1.1. Software Error Messages (Version: 7.50U)

Column 1 (A, B, C) shows the weighting of the problem

ERROR CODE ERROR MESSAGE (CAUSE) CORRECTIVE ACTIONS

A LA_AOMA001 no AOM LUT's loaded determine AOM-LUT's

C LA_AOMC002 internal error while determining AOM LUT's

C LA_AOMC003 AOM mirrors in wrong position set mirrors to correct position

C LA_AOMC004 AOM mirrors in wrong position set mirrors to correct position

A LA0000A027 power ratio GN/BL too high check gas laser

ERROR CODE ERROR MESSAGE (CAUSE) CORRECTIVE ACTIONS

C LA0000C013 PR: communication error check connectors and cables

A LAMO01A024 PR: timeout power regulator RD

A LAMO01A027 PR: working point cannot be set

C LAMO01B016 PR: power loss of laser diode

C LAMO01C006 PR: laser power RD unstable

C LAMO01C016 PR: power loss of laser diode

A LAMO02A014 PR: laser power GN too low check fiber alignment

A LAMO02A025 PR: timeout power regulator GN

A LAMO02A028 PR: laser power GN cannot be set

ERROR CODE ERROR MESSAGE (CAUSE) CORRECTIVE ACTIONS

A LAMO02A031 PR: failure during initialization of laser GN check power regulator GN

A LAMO02A040 PR: monitor diode GN saturated check power regulator GN

A LAMO02A043 PR: power regulator GN defect check power regulator GN

C LAMO02B017 PR: power loss of laser GN

C LAMO02C007 PR: laser power GN unstable

C LAMO02C017 PR: power loss of laser GN

A LAMO03A015 PR: laser power BL too low check fiber alignment

A LAMO03A026 PR: timeout power regulator BL

A LAMO03A029 PR: laser power GN cannot be set

A LAMO03A044 PR: power regulator BL defect check power regulator

C LAMO03B018 PR: loss of laser power BL

C LAMO03C008 PR: laser power BL unstable

C LAMO03C018 PR: loss of laser power BL

Five possible causes for this problem:

1. Check the Power Monitor board (are all voltages present?)

1. Check the Power Monitor board (are all voltages present?)

Adjusting the setup values for the monitor diode gain:

1.1.4. PBL error “Densitometer: less than 5 measuring values”

1. Check the amplification values in the database (close to saturation at 4095?)

Adjusting the setup values for the monitor diode gain:

1.1.5. “PR: Failure of the 24V AOM supply (PO assembly)”

• The yellow and magenta colors are missing

both AOM drivers, green and blue, defective

• Mixed colors are reproduced wrongly:

Red is not red but yellow

AOM driver Green defective

Red is not red but magenta

AOM driver Blue defective

• The test print of X-print.txt See:

‚Black‘ is black. ‚Black‘ is dark green. ‚Black‘ is dark blue.

1.1.6. “PR: AOM characteristic curves not loaded”

Error AOM LUT’s are only checked during

Cause Once a LUT (linear, default, or specific)

LUT value pairs

LUT curve diagram

Green / blue: S-shaped curve

1.2. Image Faults / Artifacts

This chapter only provides a rough overview of image faults.